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N13 Manual PDF
N13 Manual PDF
N13 Series
ASTRA
LD Series
1987 – 1991
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CONTENTS
INTRODUCTION........................................ 5 Fuel and engine management trouble shooting ... 82
Description............................................................ 84
VEHICLE IDENTIFICATION AND Service precautions and procedures ..................... 86
GENERAL SPECIFICATIONS ................. 7 System diagnosis and adjustments...................... 89
GENERAL INFORMATION ...................... 8 Fuel supply components ....................................... 92
Tools and equipment ............................................. 8 Air flow components.............................................. 98
Safety .................................................................... 10 Electronic components.......................................... 104
General repair procedures..................................... 11 EMISSION CONTROL ............................. 117
LUBRICATION AND MAINTENANCE... 14 Introduction........................................................... 117
Specifications......................................................... 14 Crankcase ventilation system............................... 117
How to grease and oil change .............................. 14 Evaporate control system ..................................... 117
Service schedule ................................................... 17 Air preheat system — 1.6 liter engines ................ 119
Exhaust control system ........................................ 120
WHEELS AND TYRES ............................. 21
Specifications......................................................... 21 CLUTCH ...................................................... 121
How to change a road wheel ................................ 21 Specifications........................................................ 121
Tire wear trouble shooting ..................................... 22 Clutch trouble shooting......................................... 121
Care and maintenance ......................................... 23 Description............................................................ 122
Clutch unit and release mechanism..................... 123
ENGINE TUNE-UP.................................... 25 Clutch pedal ......................................................... 124
Tune-up specifications ........................................... 25 Clutch cable.......................................................... 124
Tune-up operations ............................................... 25 Clutch adjustments ............................................... 125
ROADSIDE TROUBLE SHOOTING ....... 32 MANUAL TRANSAXLE AND
Trouble shooting.................................................... 32 DRIVE SHAFTS ......................................... 126
To check ignition and electrical system ................ 33 Specifications........................................................ 126
To check fuel system ............................................ 34 Manual transaxle and drive shaft trouble shooting 126
To check mechanical system ................................ 35 Description............................................................ 128
ENGINE....................................................... 37 Transaxle assembly.............................................. 129
Specifications ........................................................ 37 Differential and final drive assembly ..................... 135
Engine mechanical trouble shooting...................... 39 Gear lever assembly ............................................ 136
Description ............................................................ 41 Drive shafts .......................................................... 137
Engine and transaxle assembly ........................... 42 AUTOMATIC TRANSAXLE ....................... 140
Manifolds............................................................... 44 Specifications........................................................ 140
Camshaft, rocker arms and tappets..................... 48 Automatic transaxle trouble shooting.................... 140
Cylinder head ........................................................ 50 Description............................................................ 141
Engine sump and oil pump pickup pipe................ 54 Transaxle fluid ...................................................... 141
Oil pump ............................................................... 55 Brake band........................................................... 142
Pistons, connecting rods and cylinder bores ........ 57 Kickdown cable .................................................... 142
Crankshaft and bearings...................................... 60 Transaxle selector linkage ................................... 142
Flywheel /drive plate............................................... 63 Neutral safety switch............................................ 142
Engine mountings.................................................. 64 Transaxle assembly .............................................. 143
Exhaust system .................................................... 66
STEERING ................................................. 145
COOLING AND HEATING SYSTEMS.... 68 PART 1. STEERING TROUBLE SHOOTING....145
Specifications ........................................................ 68 Faults, causes and remedies................................ 145
Cooling system trouble shooting ........................... 68 PART 2. MANUAL STEERING......................... 147
Heater and air conditioner trouble shooting ......... 69 Specifications........................................................ 147
Description ............................................................ 70 Description............................................................ 147
Radiator ................................................................ 70 Steering wheel...................................................... 147
Cooling fan ............................................................ 73 Steering column.................................................... 148
Thermostat............................................................ 75 Steering gear assembly ....................................... 149
Thermostat housing .............................................. 76 PART 3. POWER STEERING .......................... 152
Water pump .......................................................... 76 Specifications........................................................ 152
Welch plugs .......................................................... 76 Description............................................................ 152
Heater unit, water valve and controls................... 77 In car adjustments, checks and minor repairs..... 152
Blower fan ............................................................. 80 Steering wheel...................................................... 153
Air conditioning ..................................................... 80 Steering column.................................................... 153
FUEL AND ENGINE MANAGEMENT ... 82 Power steering pump ........................................... 153
Specifications ........................................................ 82 Power steering gear assembly............................. 154
F R O N T S U S P E N S I O N ............................ 156 ELECTRICAL SYSTEM ............................ 190
Specifications......................................................... 156 Specifications......................................................... 190
Front suspension trouble shooting ........................ 156 Battery and charging system trouble shooting....... 190
Description ............................................................ 157 Battery and starting system trouble shooting ........ 191
Steering knuckle.................................................... 157 Lighting system trouble shooting ........................... 192
Suspension unit..................................................... 159 Turn signal lamp trouble shooting ........................ 192
Control arm ........................................................... 161 Test equipment and some applications................. 193
Stabiliser bar ........................................................ 162 Battery................................................................... 194
Suspension and steering angles .......................... 163 Alternator............................................................... 196
Starter motor ......................................................... 201
Ignition system ...................................................... 206
REAR SUSPENSION ................................ 164 Steering wheel....................................................... 206
Specifications ........................................................ 164 Switches and controls........................................... 206
Rear suspension trouble shooting ........................ 164 Instrument cluster.................................................. 209
Description ............................................................ 165 Blower fan.............................................................. 209
Rear hub ............................................................... 166 Radio/cassette...................................................... 209
Suspension unit .................................................... 167 lamp units............................................................ 210
Control arm ........................................................... 169 Windscreen wiper ................................................. 213
Knuckle assembly.................................................. 170 Fuses, fusible links and relays............................. 215
Stabiliser bar ........................................................ 170 Trailer wiring......................................................... 216
Rear wheel alignment ........................................... 171 Wiring diagrams ................................................... 218
BODY ........................................................... 225
Windscreen and rear glass .................................. 225
BRAKES ...................................................... 172 Front doors........................................................... 225
Specifications......................................................... 172 Rear doors............................................................ 228
Brakes trouble shooting ........................................ 172 Engine bonnet ...................................................... 231
Description ............................................................ 174 Tailgate and lock — hatchback ............................ 231
Master cylinder...................................................... 175 Luggage compartment lid and lock — sedan ........ 233
Brake servo unit .................................................... 177 Radiator grille.............................................................. 234
Front brakes ......................................................... 178 Centre console...................................................... 234
Rear disc brakes................................................... 181 Dashboard............................................................ 235
Rear drum brakes................................................. 184
Scat belts ............................................................. 236
Handbrake cable and lever assembly ................... 186
Seats .................................................................... 236
Brake adjustments ................................................ 187
Vehicle cleaning ........................................................... 237
Brake pedal........................................................... 187
Hydraulic system................................................... 188 CONVERSION TABLES.......................... 238
INTRODUCTION
This Service and Repair Manual covers the Australian manufac-
tured Nissan Pulsar (hatchback) and Vector (sedan) N13 Series 1(J87 - 91 and
the Holden Astra LD Series 1987 - 89.
Two engines were available: a 1.8 l i t e r engine with multi-point fuel injec-
tion, and a 1.6 liter throttle body injected engine. The engines are similar
having single overhead camshafts and computer controlled fuel injection and
ignition control. There was a choice of three speed automatic or five speed
manual transaxles.
A viscous coupling limited slip differential was introduced from July 1989
to the five speed manual transaxle models of the Pulsar Q and Vector SSS.
Disc brakes are fitted at the front of a l l models, while the rear brakes are
either discs or drums.
All models are equipped with independent coil spring suspension. Steering
can be by either manual or power assisted rack and pinion.
This manual includes information on trouble shooting, lubrication and
maintenance, specifications and the removal, installation and overhaul of com-
ponents which are considered to be within the scope of the average, well
equipped home mechanic.
Certain repair jobs covered in this manual require the use of special
equipment not normally found in a home tool kit. When such equipment is
required, the equipment and its function is brought to the users attention
underneath the heading for that component. Some jobs, such as automatic
transmission overhaul, should he left to an authorized dealer or a specialist
who has the extensive knowledge and equipment required. In these cases, the
removal and installation procedures are fully covered, enabling the unit to be
removed for repair or a reconditioned unit to be installed.
Reference in the manual to the left and right hand sides of the vehicle are
from the point of view of someone standing at the back of the vehicle and
looking forward.
Inexperienced operators should not attempt a service or repair operation
before completely reading the appropriate section (or other sections which may
be referred to) in the manual.
VEHICLE IDENTIFICATION AND
GENERAL SPECIFICATIONS
1. VEHICLE IDENTIFICATION
Inspection lamp.
Test lamp. Assorted measuring devices — inside and outside
Tachometer. micrometers, vernier calipers, wire gauges and feeler
gauges.
Timing light.
Digital multimeter. Ensure that the tools are suitable for the system of
Piston ring compressor. bolt and nut sizing on the vehicle. The range of
Valve spring compressor. vehicles covered by this manual use metric sizes.
Micrometer — inside, outside, multi range.
Vernier calipers. TOOL CARE
Assorted pullers. To ensure the longest possible life for hand tools,
When purchasing tools, it is sound advice to select it is important that time be spent maintaining them.
the highest quality that can be afforded, as the At the conclusion of each job. all tools used should
working life of cheaper tools is often very short. be washed thoroughly in kerosene or similar cleaning
solvent. Ensure that all dirt and grease is removed,
particularly from tools with moving parts such as
pliers and adjustable spanners. The tools should then
be wiped dry with a clean cloth.
Measuring devices should be given particular
attention as their accuracy can be affected if not
properly maintained. Feeler gauges should be kept
clean at all times and the blades should be wiped with
an oily cloth after use to prevent rusting.
Tension wrench, piston ring compressor and valve
spring compressor.
Damaged threads can be repaired using a die nut similar levers between the components in an attempt
on studs and bolts, and a tap on nuts and threaded to lever them apart. This can cause severe damage to
holes in castings. If the threads of a threaded hole are the sealing surfaces, particularly if the components are
damaged beyond repair, it will be necessary to drill made of alloy compounds.
and tap the hole to a larger size. Alternatively, a The components can be separated by tapping
Helicoil insert can be used to Testore the hole to the along the joint with a soft faced hammer or piece of
original thread size. wood. Before installing a new gasket, the mating
surfaces should be cleaned of all traces of old gasket
STUDS material and sealant.
The simplest method for removing studs is to lock Check that the new gasket is correct by comparing
two nuts together on the threaded section. The stud the bolt holes and passages on the component face
should then be able to be removed by applying an with the openings in the gasket.
unscrewing action to the lower nut. Cork and paper gaskets which have been stored
Alternatively, there are various makes of stud for some time may suffer from shrinkage. This can be
extracting tools available. rectified by soaking the gasket in water.
BEARINGS AND BUSHES
If the correct equipment is not available when
removing and installing bearings and bushes, it is
often possible to improvise.
Bearings can often be removed from shafts by
tapping alternately on opposite sides with a hammer
and drift.
OIL SEALS
Oil seals can usually be removed by levering out
with a flat screwdriver or other suitable lever. Care
should be taken not to damage the surface of the
component which the seal lip runs on.
Seals can also be removed by inserting a number
of self tapping screws into the seal body. The seal can
then be withdrawn using pliers gripping the self A simple bush installing tool using a bolt, nut and two
washers.
tapping screws.
Always apply a smear of grease or oil to the seal lip
prior to installation to provide initial lubrication. If a press is unavailable, bushes can be installed by
Unless otherwise stated, oil seals should always be placing the bush and component between the jaws of a
installed with the lip facing inwards or towards the vice and screwing the jaws together until the bush is
substance to be sealed. During installation, the seal lip fully inserted. A vice can also be used to remove
should be protected from damage from sharp com- bushes by using suitably sized spacers against either
ponents such as shaft splines by wrapping tape around vice jaw, one bearing on the bush and the other on the
the sharp edges. component. This method can also be used with a G
Install the new seal using a wooden block, or a clamp.
socket or length of tube of the appropriate diameter. A simple removing and installing tool can be
Ensure that the seal is installed squarely or distortion made using a long bolt, large and small washers, a nut
and subsequent leakage may occur. If an installation and a tubular spacer. Refer to the illustrations for the
depth is not specified, the seal should be installed method and applications.
flush with the component surface. Rubber bushes and bushes in blind holes can be
removed using an expanding type masonry bolt
GASKETS (Rawlbolt Loxin). Install a neat fitting masonry bolt to
the bush. Install and tighten the bolt until it grips the
When separating mating components (i.e. bush. The bolt and bush can then be removed using a
cylinder slide hammer or levers.
head and cylinder block), do not insert screwdrivers or
General Information 13
Location of the engine sump drain plug. Removing the engine oil filter using a filter removal tool.
Lubrication and Maintenance 15
manual transaxle. Using a finger, check that the oil is Location of the manual transaxle drain plug.
level with the bottom of the plug hole. Overfilled units
should be drained to the correct level. (9) Using a funnel, fill the engine with the
If the oil level is low, use an oil gun to fill the specified amount and grade of engine oil. start the
transaxle to the correct level. engine and run it for a few minutes. Ensure that the
When satisfied that the oil level is correct, install oil light goes out. Stop the engine, wait for a few
the plug and tighten firmly. Wipe around the plug minutes and check the engine oil on the dipstick. If
after installation. necessary add oil to bring the level to the full mark on
NOTE: On automatic transaxle vehicles, the dipstick.
refer to the Automatic Transaxle section for NOTE: To prevent overfilling the engine
the checking and topping up procedure. initially, it is good policy not to pour all the
oil into the engine in one go as sometimes sump drain plug and oil filter if a new filter was
the amounts specified are only approximate. installed.
If is best to hold back at least half a liter and (11) Referring to the service schedule, lubricate
top up the level after the engine has been run and check all other items which coincide with the
for a few minutes. grease and oil change intervals.
(10) Check thoroughly for oil leaks at the engine (12) Lower the vehicle to the ground.
Lubrication and Maintenance 17
2. SERVICE SCHEDULE
Chock the front and rear of the wheel diagonally View of the jack correctly installed to the rear jacking
opposite the wheel being changed. point.
22 Wheels and Tires
ENGINE TUNE-UP
CAUTION: To prevent severe electrical shock, extreme care must be taken when
working on or near the electronic ignition system as dangerous high tension voltages
are produced in both the primary and secondary circuits. See the text for
precautionary notes.
1. TUNE-UP SPECIFICATIONS 1.8 Liter Engine
(1) Release the clamp securing the air intake
Firing order................................................... 1 -3-4-2 hose to the throttle body and disconnect the throttle
Spark plugs: cable from the support bracket.
Type.............................................NGK BPR 6ES (2) Release the clips retaining the upper air
Gap ...........................................................1.1 mm cleaner housing to the lower air cleaner housing and
Tightening torque...................................... 20 Nm raise the upper housing while disconnecting the air
Ignition timing with diagnostic link intake hose from the throttle body. Remove the air
connector jumped...........................10 deg BTDC cleaner element.
Idle speed (ECU controlled):
Manual transaxle 1.8 liter............ 850 ± 50 rpm
Manual transaxle 1.6 liter............ 800 ± 50 rpm
Automatic transaxle
(Park or Neutral).......................... 825 ± 50 rpm
Drive belt deflection:
Alternator ........................................... 14-16 mm
Power steering pump ......................... 14-16 mm
Air conditioner compressor .................. 9-11 mm
NOTE: When performing an engine tune-
up, a/ways compare the above Specifications
with the emission control information label
inside the engine compartment.
2. TUNE-UP OPERATIONS
Special Equipment Required:
The air cleaner element should be renewed at 40 000
To Test Compression — Compression gauge km intervals. 1.8 liter engine.
TO SERVICE AIR CLEANER (3) Clean the inside of the air cleaner housing
The air cleaner is equipped with a paper element. using a damp rag to remove all traces of dust and
The element should be regularly inspected but should check the upper housing and air inlet hose for cracks
not be cleaned in service. and air leaks. Renew if necessary.
The element should be renewed every 40 000 km. (4) Install a new air cleaner element to the lower
This distance is only a guide for normal operating housing ensuring that the element is correctly seated
conditions and should be reduced accordingly if the around the edges.
vehicle is operating under extremely dusty conditions. (5) Install the upper housing and lock the clips,
NOTE: Paper air cleaner elements should securing it to the lower housing. Connect the air
not be washed in petrol or any other type of intake hose to the throttle body and the throttle cable
cleaning solvent. If the element has been to the support bracket. Tighten the hose clamp
washed in solvent or has become oil soaked, securely.
(6) Start the engine and check the air cleaner
it should be discarded and a new element assembly for air leaks.
installed.
26 Engine Tune-up
1.6 Liter Engine (b) Disconnect the fuel pump wiring connector.
(1) Remove the nuts and washers securing the (c) Start and run the engine until it stalls.
upper air cleaner housing to the lower air cleaner Operate the starter motor for 10 seconds to ensure
housing and release the retaining clips. that the fuel pressure has dissipated.
(2) Remove the air cleaner element. (2) Disconnect the negative battery terminal.
(3) Clean the inside of the air cleaner housing (3) Release the hose clamps and disconnect the
using a damp rag to remove all traces of dust. fuel hoses from the filter. Remove the filter from the
(4) Install a new air cleaner element ensuring that retaining clamp noting the direction of the arrow on
the element is correctly seated around the edges. the filter body.
(5) Install the upper housing and secure the On some models it will be necessary to remove the
retaining clips. Tighten the retaining nuts securely. screw from the side of the clamp to allow the filler to
be removed.
TO RENEW FUEL FILTER Installation is a reversal of the removal procedure
with attention to the following points:
filter should (1) Install the fuel filter with the arrow facing the
The fuel be renewed every direction noted on removal, that is, in the direction of
40 000 km. fuel flow.
(1) Depressurize the fuel system using the fol- (2) Ensure that the hose clamps are tightened
lowing procedure: securely.
(a) Lift the front edge of the rear seat cushion (3) Connect the fuel pump wiring connector and
and remove the cushion from the vehicle. install the rear seat cushion.
(4) Start the engine and check for fuel leaks.
Rectify as necessary.
TO ADJUST DRIVE BELTS
It is essential that all drive belts are adjusted to
the correct tension to prevent slippage or premature
wear of the bearings in the alternator and, if equipped,
the power steering pump and air conditioner compres-
sor.
(1) Push down on the drive belt with a 10 kg
force midway between the pulleys of the drive belt
concerned.
On models with air conditioning, push down on
the upper section of the drive belt between the
compressor and crankshaft pulleys.
If the drive belt deflection is not within Specifi-
cations it will require adjustment as follows.
When depressurizing the fuel system, remove the rear (2) Loosen the alternator and, if equipped, the
seat cushion and disconnect the fuel pump wiring power steering pump pivot and adjusting bolts and
connector.
ALTERNATOR
Timing Light
(1) Connect the timing light to the engine fol-
lowing the instrument manufacturers instructions.
NOTE: Do not connect or disconnect the
timing light with the engine running as
voltage surges could damage the alternator.
Do not allow the high tension leads to open View showing the location of the diagnostic link
circuit as damage to the ignition system connector. Passengers seat removed for clarity.
could result. Inset shows the diagnostic link connector terminal
identification.
(2) Where necessary, connect the power leads of
the timing light to an external power source to prevent
possible transient voltages in the timing light damag- (2) Start the engine and allow it to reach normal
ing the vehicle alternator. operating temperature.
(3) Connect a jumper lead between terminals A
and B on the diagnostic link connector.
Tachometer (4) With the engine idling at the specified speed,
(1) Ensure that the tachometer is compatible check the ignition timing with the timing light.
with the vehicle ignition system. Correct timing exists when the marks on the
(2) Disconnect the resistor from the tachometer crankshaft pulley are aligned with the pointer on the
inner timing cover.
Engine Tune-up
This section deals with the common causes of jump starting, or being jump started by
engine failure to start, as inevitably there will come a another vehicle. If available use jumper
time when every driver will experience this problem leads equipped with a surge protection de-
and will therefore need to call upon his own resources vice and follow the lead manufacturers in-
to rectify the trouble. Roadside breakdowns other structions carefully, particularly regarding
than engine failure can be identified by reference to the connection and disconnection of the
the Trouble Shooting section on the particular com- leads.
ponent affected. (1) Ensure that the booster battery is 12 volts
and the negative terminal is earthed.
(2) Ensure that the vehicles are not touching and
1. TROUBLE SHOOTING that the ignition and all accessories on both vehicles
are switched Off.
Trouble shooting is only a process of elimination (3) Ensure that the transmissions on both vehi-
and provided the procedure is carried out correctly cles are in Park or Neutral and the handbrakes are
and systematically an accurate diagnosis of the trouble firmly applied.
can be made in the minimum amount of time. (4) Remove the vent caps from the battery and
For an internal combustion engine to run there check the electrolyte level. Replenish with distilled
are three basic requirements, these are ignition, fuel water as necessary.
and compression. There are other factors of course
but as a rule an engine's failure to start can be
attributed to a fault in one of these three systems.
Reports from field engineers of motoring organi-
sations prove that the biggest percentage of engine
breakdowns are in the order of ignition or electrical
failure first, followed by fuel, with mechanical or
compression failure the least common.
Should the engine fail to start, first check that
there is adequate fuel in the tank and if so. carry out
the following checking procedures in the order de-
scribed.
ing the wiring from any component, ensure (b) Check the distributor cap to ensure that it is
that the ignition switch is off and the dry and clean. Examine both the inside and outside of
negative battery terminal is disconnected to the cap for cracks or tracking, particularly between the
prevent damage to the solid state circuitry. high tension lead segments.
Check that the carbon brush in the centre of the
(4) Open the electrode gap of a serviceable spark distributor cap interior face is clean and dry and
plug to 6 mm. Securely earth the plug using a jumper ensure that the brush moves freely in and out of its
lead or by tying the plug to an earthed engine locating hole.
component. (c) Check the rotor arm for cracks, deposits and
(5) Disconnect the high tension lead from a burning on the metal arm.
spark plug and connect it to the test spark plug. (d) Ensure that the high tension leads have dry.
(6) Have an assistant operate the starter motor. clean and secure connections on the distributor cap.
(7) Check that a spark, if any, jumps the gap on (8) If the above checks result in a good spark at
the test spark plug. the spark plug high tension leads but the engine is still
If the spark is satisfactory, proceed to operation not operating satisfactorily, remove all the spark plugs
(8). and check the condition and electrode gap as de-
If there is no spark, proceed as follows: scribed in the Engine Tune-up section under the
(a) Check the high tension leads to ensure that appropriate heading.
they are dry and that the insulation is not cracked or
perished. Check the ends of the leads for burning.
Using an ohmmeter, measure the resistance in
each high tension lead. The resistance should be no 3. TO CHECK FUEL SYSTEM
more than 15 000 ohms per lead.
Due to the complex nature of the EFI system, it is
recommended that should the following checks prove
satisfactory but the engine fail to start, reference be
made to the Fuel and Engine Management section of
this manual or a Nissan workshop be consulted.
(1) Check that the fuel tank contains a reason-
able amount of fuel.
(2) Have an assistant switch the ignition on and
off while squeezing the fuel supply hose with the
fingers. If the fuel pump is operating it should be
possible to feel the fuel pressure increase for approx-
imately two seconds.
NOTE: When conducting the above test it
should be possible to hear the fuel pump and
ignition relays clicking when the ignition is
switched on and off
Check the spark plug high tension leads for cracks and If the fuel pump relay fails, power will be
burnt or corroded terminals. supplied to the fuel pump via the oil pressure
Check the distributor cap for cracks or tracking Squeeze the fuel supply hose while the ignition is
between the terminals. switched On. An increase in pressure should be felt.
Roadside Trouble Shooting 35
View showing the location of the fuel pump fuse and Check that the MAP sensor hose is not blocked or split
the EGI and fuel pump relays. and ensure that all electrical connections are clean and
secure.
switch. When starting the engine, the fuel
pump will not operate until the oil pressure If flooding persists, refer to the Fuel and Engine
is sufficient to extinguish the oil pressure Management section.
warning lamp. Therefore it will be necessary (6) Check that all EFI electrical wiring connec-
to operate the starter motor for a longer tors are clean and secure.
period than usual to start the engine. (7) Check that the MAP sensor vacuum hose is
(3) If the fuel pump cannot be felt operating, securely connected at each end and is not split or
check the fuel pump fuse located in the fuse panel blocked.
adjacent to the steering column.
If the fuel pump fuse is serviceable, refer to the
Fuel and Engine Management section for detailed 4. TO CHECK MECHANICAL SYSTEM
tests on the fuel pump.
(4) Check that all fuel hose connections are The following check procedure assumes that the
secure. starter motor will rotate the engine. If not, on manual
(5) Remove the spark plugs and check for petrol transaxle models, depress the clutch pedal to disen-
saturation of the electrodes which indicates flooding. gage the engine from the transaxle in case the fault lies
Thoroughly clean and dry the spark plugs before within the transaxle.
replacement. If the starter motor will not rotate the engine, it
Fully depress the throttle pedal and turn the will be necessary to remove the starter motor and
ignition switch to the start position. If the engine does attempt to turn the engine over manually. This will
not start, proceed as follows. establish whether the fault lies with the starter motor,
which could be jammed or defective, or with the
engine, which could be seized or have broken internal
components such as connecting rods, pistons and
crankshafts etc.
If the starter motor is not at fault and the engine
will not rotate manually, refer to the Engine Mechan-
ical Trouble Shooting heading in the Engine section.
It should be noted that the only way that cylinder
compression can be accurately tested is with a com-
pression gauge. The method described in the following
procedure is only intended to give a rough indication
when checking for causes of engine breakdown,
( I ) When the engine is cool, check for loss of
coolant from the cooling system.
If coolant loss is evident, check carefully for any
indication of external leakage. Remove the engine oil
dipstick and check for water contamination (emulsi-
Ensure that all fuel connections are securely tightened. fication) of the oil. When oil mixes with water it will
36 Roadside Trouble Shooting
ENGINE
Oil pump cover plate screws............................ 6 Nm gasket and valves prove satisfactory, inspect
Oil pump mounting bolts.................................. 6 Nm the cylinder bores, pistons and rings.
Oil pump pickup bolts Check for air leaks at the inlet manifold
(coat with Loctite 242) ..................................... 8 Nm by applying engine oil around the manifold
Sump bolts (coat with Loctite 242).................. 5 Nm joints. If the oil can be seen or heard sucking
Sump drain plug ..............................................35 Nm into the manifold or excessive smoke begins
*Use new bolts to issue from the exhaust system, there is an
Head bolts maximum torque 135 Nm air leak at the inlet manifold.
NOISY VALVE OPERATION
1. ENGINE MECHANICAL TROUBLE (1) Faulty hydraulic tappets: Renew the faulty
SHOOTING tappet assemblies.
(2) Weak or broken valve springs: Remove the
camshaft housing top cover and check the condition
ENGINE MISSES AT IDLING SPEED of the valve springs.
NOTE: For other causes of engine misfire, (3) Worn valve guides: Overhaul the cylinder
refer to the Fuel and Engine Management head as described in this section.
section. (4) Worn rocker gear: Remove (he rocker gear
and check the components for wear.
(1) Blown head gasket: Check the cylinder com-
pressions and renew the head gasket as necessary.
(2) Burnt valves or seats in the cylinder head:
Check the cylinder compressions and overhaul the
cylinder head as necessary.
(3) Broken or worn piston rings: Check the
cylinder compressions and renew the piston rings as
necessary.
(4) Weak or broken valve springs: Remove the
camshaft housing top cover and check the condition
of the valve springs.
(5) Air leak at the inlet manifold gasket; Check
for air leaks by applying oil around the manifold
joints. Renew the gasket if an air leak is evident.
NOTE: Use a compression gauge and check
the compression pressure in each cylinder as
described in the Engine Tune-up section. If
a low pressure reading is indicated in one or Camshaft lobe wear is also a cause of noisy valve
more cylinders, remove the cylinder head for operation.
gasket and valve inspection. Should the
BIG END BEARING NOISE
(1) Inadequate oil supply: Check the oil level in
the sump and the condition of the oil pump and relief
valve. Renew the oil filter.
(2) Excessive bearing clearance: Renew the bear-
ing shells, check and regrind the big end journals if
oval or tapered.
(3) Thin oil or oil diluted by petrol or water:
Change to the correct oil grade. Check and rectify the
cause of the oil dilution. Check that the engine is not
operating in overheat conditions.
(4) Low oil pressure: Check the engine oil level.
Check the pressure relief valve and spring and the oil
filter bypass valve.
(5) Misaligned big end bearings: Align the con-
necting rods and renew the big end bearing shells.
NOTE: Big end bearing noise is indicated
Air leaks at the inlet manifold can be located by by a metallic knock which is usually loudest
applying engine oil around the suspect joints. at approximately 60 km/h with the throttle
40 Engine
The cylinder block is a cast iron alloy, deep skirt (9) On 1.6 liter models, remove the air cleaner
design and the crankshaft is supported in the cylinder assembly. Refer to the Fuel and Engine Management
block by five precision insert replaceable main bear- section if necessary.
ings. Crankshaft end float is controlled by the flanged (10) Disconnect the throttle cable from the throt-
centre main bearing. Connecting rods are I section tle body and from the camshaft housing top cover
forgings equipped with precision insert replaceable big bracket, if applicable.
end bearings. The gudgeon pins are an interference fit (11) Disconnect the fuel supply and return hoses.
in the connecting rod and a floating fit in the piston. Mark the hoses as an aid to installation.
The cast aluminum pistons are equipped with (12) Suitably mark and disconnect the charcoal
two compression rings and one oil control ring. canister hoses.
The twin rotor, involute gear oil pump is mounted (13) Disconnect the injector wires from the injec-
directly to the front face of the cylinder block. The tors. On 1.6 liter models, slide the wiring out from the
inner rotor is internally driven by the crankshaft. The throttle body.
oil pump pressure relief valve is not adjustable, and (14) Disconnect the wiring from the throttle po-
consists of a plunger and spring mounted in the oil sition sensor (TPS), idle air control (IAC) valve,
pump body. oxygen (O2) sensor wire, coolant temperature sensor,
The pump draws oil through a screen in the sump coolant sender and on 1.8 liter models, the manifold
and delivers it, via a full flow replaceable oil filter, to air temperature (MAT) sensor.
the oil gallery from where it is distributed to the (15) Disconnect the wiring connector adjacent to
hydraulic tappets, camshaft and crankshaft bearings the top heater hose, the wiring from the alternator and
and to the overhead rocker and valve mechanism. the two earth wires from underneath the cylinder head
bolts.
(16) Lay the wiring loom over on the passenger
3. ENGINE AND TRANSAXLE ASSEMBLY side of the engine compartment, clear of the work
area.
Special Equipment Required: (17) On manual transaxle models, loosen the
To Remove and Instill — Suitable lifting tackle, clutch cable adjusting nuts and remove the cable
extra long chassis stands, suitable trolley through the slot in the lever. Remove the clutch cable
bracket from the transaxle after removing the retain-
TO REMOVE ing bolts and place the cable to one side.
(18) Disconnect the wiring from the starter mo-
NOTE: Due to the high residual pressure tor, speedometer sender and on manual transaxle
within the fuel system, it will be necessary to models, the reverse lamp switch wiring.
depressurize the system before removing any (19) If applicable, disconnect the power steering
fuel supply components. Refer to the Fuel lines from the pump and drain the fluid into a
and Engine Management section for the container. Suitably plug the lines and the pump to
correct procedure. prevent the entry of dirt.
(1) Disconnect the negative battery terminal. (20) On automatic transaxle models, disconnect
(2) Mark around the bonnet hinges with a soft the selector cable and bracket from the transaxle
lead pencil Co facilitate correct installation. With the assembly.
aid of an assistant, remove the bonnet retaining bolts Disconnect the transaxle oil cooler lines from the
and remove the bonnet from the vehicle. transaxle. Plug the lines and fittings to prevent the
(3) Drain the engine and transaxle lubricant. entry of dirt etc.
(4) Open the coolant drain tap located on the (21) Loosen the front wheel nuts, raise the front
lower radiator pipe and drain the coolant. of the vehicle and support it on extra long chassis
(5) Loosen the hose clips and disconnect the stands. Ensure that the vehicle is high enough to allow
heater hoses from the heater pipes at the bulkhead. removal of the engine from underneath.
(22) Remove the front wheels and the engine
NOTE: Do not use excessive force to remove splash guards from the vehicle.
the heater hoses from the heater pipes or the (23) On manual transaxle models, remove the
heater core will become dislodged from the stay rod and control rod bolts and nuts and disconnect
heater unit. If necessary, cut the heater the rods from the transaxle.
hoses from the pipes using a sharp knife. (24) Remove the lower control arm to steering
(6) Loosen the hose clamps and disconnect the knuckle ball joint nuts and separate the ball joints
radiator hoses from the engine assembly. from the steering knuckle by holding a dolly or a
(7) Disconnect the positive lead from the bat- hammer against one side of the steering knuckle and
tery. hitting the other side with a hammer. The taper on the
(8) On 1.8 liter models, disconnect the air inlet ball joint will release from the steering knuckle.
duct. (25) Pull the steering knuckles outward swiftly to
Engine 43
Front view of the 1.8 liter engine and automatic transaxle assembly removed from the vehicle.
release the driveshafts from the transaxle. Tie the one side, clear of the work area, with wire or similar.
driveshafts to the underbody of the vehicle using wire NOTE: Do not disconnect the hoses from
and ensuring that excessive strain is not placed on the the air conditioning compressor. Escaping
joints. refrigerant can cause frostbite and eye dam-
NOTE: If the driveshafts will not release age.
from the transaxle, a lever can be used
between the driveshaft and the transaxle. (31) Lower the engine and transaxle assembly
Care must be taken when using the lever not onto a suitable trolley and maneuver the engine from
to damage the transaxle oil seals. beneath the vehicle.
(26) Remove the engine pipe from the engine.
Refer to the procedure at the end of this section if
necessary. TO INSTAL
(27) Remove the engine crossmember retaining Installation is a reversal of the removal procedure
bolts and nuts and remove the crossmember from with attention to the following points:
beneath the vehicle. (1) Position the engine and transaxle assembly
(28) Attach the lifting tackle to the engine and beneath the front of the vehicle.
raise the engine slightly to take the weight off the (2) Install the lifting tackle and raise the engine
engine mountings. assembly into position in the engine compartment.
(29) Remove the front, rear, left and right engine
mounting bolts and nuts. Withdraw the mountings NOTE: On air conditioned models, ensure
from the engine compartment. that the air conditioning compressor is in-
(30) Slowly lower the engine and transaxle assem- stalled to the engine as the engine is in-
bly from the engine compartment. stalled to the engine compartment.
On air conditioned vehicles, remove the air (3) Install the engine and transaxle
conditioning compressor and hoses after the engine assembly
has been lowered slightly. Secure the compressor to mounting nuts, bolts and washers finger tight before
the full weight of the assembly is taken by the
44 Engine
Rear three quarter view of the 1.8 liter engine and automatic transaxle assembly.
mountings. Lower the assembly onto the mountings depressurise the system before removing the
and tighten the mounting nuts and bolts. fuel supply components. Refer to the Fuel
(4) Install a new exhaust flange gasket. and Engine Management section for the
(5) Fill the engine and transaxle with the correct correct procedure.
quantity and grade of lubricant. (1) Disconnect the negative battery terminal.
(6) Fill the cooling system as described in the (2) Remove the wingnuts retaining the air
Cooling and Heating Systems section. cleaner to the throttle body, lift the air cleaner
(7) On models with power steering, fill the power upwards slightly and disconnect the vacuum hoses.
steering reservoir with the recommended fluid. (3) Drain the cooling system as described in the
(8) Start and run the engine until it reaches the Cooling and Heating Systems section.
normal operating temperature and check for fuel, oil (4) Loosen the hose clamps and disconnect the
and coolant leaks. engine coolant hoses from the rear of the manifold.
(5) Disconnect the small branch of the engine
ventilation hose from the rear of the inlet manifold.
4. MANIFOLDS (6) On automatic transaxle models, disconnect
the kickdown cable from the throttle lever by releasing
INLET MANIFOLD - 1.6 Liter Models the wire spring clip and removing the cable end socket
from the ball.
To Remove and Install (7) Turn the throttle lever to the full throttle
NOTE: Due to the high residual pressure position. Using the slack in the throttle cable, release
within the fuel system, it will be necessary to the throttle cable end through the slot provided.
Engine 45
(1) Ensure that all carbon and old gasket mate- Installation is a reversal of the removal procedure
rial is cleaned from the manifold and cylinder head with attention to the following points:
faces. (1) Ensure that all carbon is cleaned from the
(2) Check the face of the manifold for distortion manifold and cylinder head mating surfaces.
using a straight edge and a feeler gauge. (2) Check the face of the manifold for distortion
(3) Use a new gasket and ensure that the mani- using a straight edge and feeler gauges.
fold retaining nuts are tightened to the specified (3) Use new gaskets on assembly.
torque in a spiral pattern from the centre outwards. (4) Tighten the exhaust manifold retaining nuts
(4) Adjust the throttle cable as described in the to the specified torque in the sequence shown in the
Fuel and Engine Management section and the kick- illustration.
down cable as described in the Automatic Transaxle (5) Install the oxygen sensor. Refer to the Fuel
section. and Engine Management section.
(5) Start the engine and check for air, fuel and (6) Coat the threads of the front exhaust pipe to
water leaks. manifold retaining nuts with an anti-seize solution
and tighten the nuts to the specified torque.
EXHAUST MANIFOLD
5. CAMSHAFT DRIVE BELT
To Remove and Install
(1) Bring the engine to operating temperature Special Equipment Required:
and remove the oxygen sensor. To Adjust — Drive belt adjusting tool
(2) Disconnect the negative battery terminal.
(3) On 1.6 liter models, remove the air cleaner TO REMOVE
nuts, disconnect the vacuum hose and withdraw the
air cleaner from the vehicle. (1) Disconnect the negative battery terminal.
(4) Remove the front exhaust pipe flange mount- (2) Raise the front of the vehicle, support it on
ing nuts and separate the exhaust pipe from the chassis stands and remove the right hand front wheel.
manifold. Refer to the Wheels and Tires section.
(5) Remove the heat shield retaining bolts and (3) Remove the fasteners securing the engine
withdraw the heat shield from the exhaust manifold. splash guard to the right hand front inner mudguard
(6) Remove the exhaust manifold to cylinder and remove the splash guard.
head retaining nuts and remove the manifold from the (4) Loosen the alternator adjusting bolt and if
engine. Discard the manifold gasket. equipped, the power steering and air conditioning
adjusting bolts. Remove the drive belt(s).
View of the 1.8 liter engine with the upper timing belt
cover removed showing the camshaft gear timing
View of the exhaust manifold and components showing marks. Inset shows the crankshaft pulley timing
the correct tightening sequence. marks.
Engine 47
(4) Ensure that the tappet assemblies are full of (5) Clean the seal recess and the camshaft sea!
clean engine oil and insert the tappets in their running surface.
respective bores in the cylinder head. Install the thrust (6) Lubricate the lip of a new oil seal with engine
pads to the top of each valve assembly ensuring that oil and slide the seal over the camshaft. Ensure that
they are returned to their original location. the lip of the seal faces towards the inside of the
(5) Coat the contact surfaces of the rocker arms camshaft housing. Tap evenly around the edges of the
with molybdenum disulphide grease and install the seal until it is fully seated in the camshaft housing.
rocker arms to their original locations on the cylinder (7) Install the camshaft timing gear to the cam-
head. shaft, ensuring that it is correctly located. Tighten the
(6) Clean the mating surfaces of the camshaft camshaft timing gear retaining bolt to the specified
housing and cylinder head. Apply a bead of Loctite torque. Do not allow the camshaft to rotate while
515 to the cylinder head and camshaft housing mating tightening the bolt.
surfaces. Take care that no sealant is forced into the (8) Install and adjust the drive belt as described
oil passages and install the camshaft housing to the under the previous heading. Ensure that the timing
cylinder head. marks are aligned.
(7) Install new cylinder head bolts and lubricate (9) Install the camshaft housing top cover using a
the bolts and washers with oil. new gasket. Tighten the retaining bolts to the specified
(8) Apply an initial torque to the cylinder head torque.
bolts of 25 Nm in the correct sequence as shown in
the illustration under the Cylinder Head heading. 7. CYLINDER HEAD
Further tighten the head bolts in the correct sequence,
in three separate 60 degree stages. Refer to Specifica- Special Equipment Required:
tions. To Dismantle and Assemble — Valve spring com-
(9) Install the bolts securing the camshaft pressor
drive To Inspect — Dial gauge and straight edge
belt inner cover to the camshaft housing. To Install — Drive belt adjusting tool
(10) Install the camshaft timing gear to the cam-
shaft ensuring that it is correctly located. Tighten the TO REMOVE AND INSTAL
camshaft timing gear retaining boll to the specified
torque. NOTE: Due to the high residua! pressure
(11) Install and adjust the camshaft drive belt as within the fuel system, it will be necessary to
described under the previous heading. depressurize the system before removing any
(12) Install the distributor. Refer to the Fuel and fuel supply components. Refer to the Fuel
Engine Management section. and Engine Management section for the
(13) Connect the lower radiator hose and fill the correct procedure.
cooling system with the required coolant. Refer to the Allow the engine to cool prior to the
Cooling and Heating Systems section if necessary. removal of the cylinder head to prevent
(14) Start and run the engine until normal oper- possible distortion of the cylinder head.
ating temperature is attained and tighten the cylinder (1) Disconnect the negative battery terminal and
head bolts another 30-50 degrees in the correct remove the nuts securing the earth wires to the
sequence, ensuring that the tension does not exceed cylinder head bolts.
135 Nm. (2) Remove the camshaft drive belt as previ-
ously described.
TO RENEW CAMSHAFT OIL SEAL, (3) Disconnect the lower radiator hose and drain
CAMSHAFT INSTALLED the cooling system. Refer to the Cooling and Heating
Systems section if necessary.
(1) Remove the camshaft drive belt from the (4) Remove the alternator adjusting bracket
camshaft timing gear as described under the previous mounting bolt and insulating washers from the inlet
heading. manifold. Loosen the adjusting bolt at the alternator
(2) Remove the camshaft housing top cover and slide the bracket away from the cylinder head.
retaining bolts, remove the cover and discard the (5) Disconnect the upper radiator hose, coolant
gasket. by-pass hose and the heater hose from the thermostat
(3) Use an open end spanner to hold the cam- housing and on 1.6 liter models, the coolant hoses
shaft between the inlet and exhaust lobes of number from the inlet manifold.
four cylinder and remove the camshaft timing gear (6) Disconnect the electrical connectors from the
retaining bolt and the camshaft timing gear. throttle body, fuel injectors, coil, distributor and on
(4) With a pointed drift, tap a small hole in the 1.8 liter models, the MAT sensor.
front face of the oil seal. Insert a self tapping screw in (7) Disconnect the oxygen sensor wiring connec-
the hole and using a pair of pliers, pull on the screw tor and remove the wiring connectors from the
to remove the oil seal from the housing.
Engine 51
in the valve stem groove before releasing the spring the oil has been drained.
compressor. A sharp tap to the top of the valve stem (4) Remove the engine pipe as described at the
with a soft faced hammer will ensure that the collets end of this section.
are correctly seated. (5) Remove the nuts and bolts retaining the
(7) Install the inlet and exhaust manifolds using engine crossmember to the vehicle underbody and
new gaskets and tighten the mounting nuts to the withdraw the crossmember from the vehicle. On
specified torque as previously described. automatic transaxle models, it will be necessary to
(8) Install a new sealing ring to the release the selector cable from the crossmember
thermostat bracket.
housing, install the housing to the cylinder head and (6) Remove the sump retaining bolts and wash-
tighten the mounting bolts to the specified torque. ers and if necessary firmly bump the sump with the
(9) Ensure that the lappet assemblies are filled palm of the hand and remove it from the engine.
with clean engine oil and install the tappets in (7) Remove the bolts retaining the oil pump
their pickup pipe to the oil pump and disconnect the
respective bores in the cylinder head. pickup pipe from the support bracket. Remove the
(10) Install the thrust pads to the top of each pickup pipe and discard the O ring seal.
valve (8) Remove the scraper and gasket from the
assembly, ensuring that they are returned to their engine.
original locations. (9) Clean the gasket material from the sump,
(11) Coat the contact surfaces of the rocker arms engine block and the scraper.
with molybdenum disulphide grease and install the
rocker arms to their original locations on the cylinder NOTE: If the scraper assembly is damaged
head. it should be renewed.
(12) Install the cylinder head to the engine as
previously described.
TO INSTAL
8. ENGINE SUMP AND OIL PUMP PICKUP (1) Wash the inside of the sump to remove
. PIPE carbon and sludge deposits. Check for any metal
deposits which may indicate an imminent component
TO REMOVE failure.
(1) Disconnect the negative battery terminal. (2) Inspect the sump for dents and cracks.
(2) Raise the front of the vehicle and support it Ensure that the gasket sealing face is not distorted or
on chassis stands. Refer to the Wheels and Tires damaged.
section for the correct procedure. (3) Clean the pickup pipe screen with solvent
(3) Remove the sump plug and drain the engine and a brush.
oil into a container. Install and tighten the plug (4) Using a new O ring seal, install the pickup
pipe. Coat the pipe retaining bolts with Loctite 242
after and tighten to the specified torque.
(5) Apply a bead of KP510-00150 sealer or
equivalent to the oil pump to cylinder block mating
joint area.
(6) Ensure that the sump gasket is correctly
located on the scraper and install the sump to
the
engine. Apply Loctite 242 to the threads of the sump
bolts and tighten the bolts to the specified torque.
(7) Install the front exhaust pipe using a
new
gasket and coat the threads of the flange nuts with an
anti-seize compound before tightening the nuts to the
specified torque.
(8) Install the engine crossmember and
tighten
the nuts and bolts securely. If applicable, connect the
automatic transaxle selector cable to the crossmember
bracket.
(9) Ensure that the sump drain plug is secure
and lower the vehicle to the ground.
(10) Fill the engine with the specified amount and
grade of engine oil. Refer to the Lubrication and
Maintenance section if necessary.
View of the sump, oil pump pickup, gasket and scraper (11) Start and run the engine and check for oil
removed from the engine. leaks.
Engine 55
9. OIL PUMP
TO REMOVE AND DISMANTLE
(1) Disconnect the negative battery terminal.
(2) Disconnect the lower radiator hose and drain
the cooling system.
(3) Raise the front of the vehicle and support it
on chassis stands. Refer to the Wheels and Tires
section if necessary.
(4) Remove the right hand front wheel.
(5) Remove the fasteners securing the engine
splash guard to the right hand front inner mudguard
and remove the splash guard.
(6) Remove the engine sump and oil pump
pickup pipe as previously described. Remove the oil
filter.
(7) Remove the camshaft timing belt as de-
scribed previously.
(8) Disconnect the oil pressure sender electrical
connector.
(9) Using a socket and bar, remove the bolt and
spacer retaining the crankshaft timing gear to the
crankshaft. Discard the bolt.
NOTE: It may be necessary to lock the Dismantled view of the oil pump assembly.
crankshaft when removing the crankshaft
timing gear retaining bolt. If necessary, the cylinder block and remove the oil pump from the
insert a piece of timber between the crank- engine. Discard the gasket.
case and the crankshaft to prevent the (16) Remove the screws retaining the oil pump
crankshaft turning. cover plate and lift the cover plate from the rear of the
(10) Remove the crankshaft timing gear from the oil pump.
crankshaft. It may be necessary to lever the gear from (17) Lift the inner and outer rotors from the oil
the crankshaft using two screwdrivers. Remove the pump housing. Note that the outer rotor may be
key and spacer from the crankshaft. stamped with a mark which must face the cover plate
(11) Remove the camshaft housing top cover. on assembly.
(12) Using an open ended spanner, hold the (18) Unscrew the oil pressure relief valve plug
camshaft between the inlet and exhaust lobes of and remove the relief spring and plunger from the oil
number four cylinder and remove the camshaft timing pump housing. Discard the sealing washer from the
gear retaining bolt and the camshaft timing gear. relief valve plug.
(13) Remove the bolts securing the water pump (19) If necessary, remove the oil pressure gauge
to the cylinder block and remove the water pump. If sender unit.
necessary- refer to the Cooling and Heating Systems (20) Remove the crankshaft oil seal from the
section. pump housing.
(14) Remove the camshaft drive belt inner cover
retaining bolts and remove the inner cover. TO CHECK AND INSPECT
(15) Remove the bolts securing the oil pump to (1) Wash all the pump components thoroughly
in cleaning solvent and allow to dry.
(2) Inspect the inner and outer rotors and the
cover plate for scoring or wear. Renew the rotors
and/or the cover plate if these faults are evident.
(3) Temporarily install the rotors into the oil
pump housing. Check the backlash between the teeth
of the inner and outer rotors at the point where the
rotor teeth are most closely meshed. If the clearance at
this point exceeds the Specifications, check the rotors
and housing for wear and renew as necessary.
(4) Check the rotor end float by placing a
straight edge across the oil pump housing and measure
View of the oil pump and associated components. the clearance between the straight edge and the rotors
56 Engine
(23) Lower the vehicle to the ground and securely Compare the measurement to the Specifications
tighten the wheel nuts. and if the bearing clearance exceeds the limit, install a
new bearing on assembly.
10. PISTONS, CONNECTING RODS AND Repeat the procedure on the remaining cylinders
CYLINDER BORES and note each individual bearing clearance for assem-
bly purposes.
Special Equipment Required: NOTE: Do not rotate the engine while the
To Inspect — Micrometer, cylinder measuring Plastigage is in position or false readings
gauge will result.
To Remove Ridge from Bores — Ridge removal tool
To Deglaze Cylinder Bores — Cylinder surfacing
hone
To Install — Piston ring compressor
TO REMOVE
(1) Remove the engine sump and oil pump
pickup pipe as previously described.
(2) Remove the cylinder head as previously
described.
(3) Mark the relationship of the pistons to their
respective cylinders and the bearing caps to their
respective connecting rods by letter stamps or centre
punch marks.
(4) Measure each connecting rod for side clear-
ance on the crankpin. Refer to the illustration. If the
clearance exceeds the Specifications a new connecting
rod will have to be installed on assembly.
(5) With number one cylinder on the bottom of
its stroke, remove the bearing cap bolts and the
bearing cap.
Wipe the bearing shell and the exposed part of the
journal with a piece of clean lint free cloth, insert a
piece of Plastigage across the journal, install the
bearing cap and tighten the bolts to the specified
torque.
Remove the bolts and cap and measure (with the
scale on the packet) the spread width of the Plastigage
to determine the bearing clearance.
TO INSPECT PISTONS AND CONNECTING Replacement connecting rods are supplied only at
RODS their highest production weight and must be matched
to the weight of the remaining connecting rods by
(1) Remove all carbon deposits from the bottom filing the big end boss. For these reasons it is
of the ring grooves with a ring groove cleaning tool or recommended that the work be entrusted to a repu-
a broken ring. Use caution to avoid scoring the table engine reconditioner who will have the special-
bottom and sides of the ring groove. ised equipment and knowledge to carry out this work.
NOTE; An ideal method of removing carbon TO INSPECT CYLINDER BLOCK AND BORES
deposits from pistons is to immerse the
piston in a tank of chemical cleaner. After With the pistons removed as previously de-
soaking, the carbon can be readily hosed off scribed, carry out the following checks and measuring
with water. This method minimizes the procedures:
chance of damage through scraping, particu- (1) Check the cylinder bores for cracks, scores or
larly with aluminum alloy components. scuffs.
(2) Inspect the pistons for scuff marks, scoring or
burning.
(3) Inspect the ring grooves of the pistons for
excessive wear. Using a new piston ring, check the
clearances between the side of the ring and the ring
lands of the piston with feeler gauges. Compare the
side clearance with the Specifications.
(4) Inspect each pair of bearing shells for wear
especially on an outer edge. If one or more pairs of
bearing shells are worn on the outer edge it is possible
that the connecting rod is bent.
(5) Before renewing a piston or connecting rod,
inspect the cylinder block to see if it requires reboring
or honing.
If the cylinder block requires reboring, new over- Check for cylinder bore wear. Difference between A
size pistons will have to be installed. and B measurement at top of piston travel is out of
(6) If a piston or connecting rod is to be round dimension. Difference between A at top and at
renewed, a special tool will be required to press the bottom of piston travel is cylinder taper.
gudgeon pin from the connecting rod. To install the
piston and gudgeon pin to the connecting rod, the (2) Using an accurate cylinder gauge, measure
gudgeon pin boss must be accurately heated to 280 each cylinder bore for wear. Take the measurements,
degrees C before the gudgeon pin can be inserted in at the upper and lower sections of the bore in two
the little end of the connecting rod. directions — along and across the cylinder block.
Refer to the illustration.
(3) If the wear in any cylinder exceeds the
specified limit, rebore and hone all the cylinders to the
nearest oversize for pistons and rings.
(4) With a straight edge and feeler gauge, check
the top face of the cylinder block for distortion, using
the same procedure described for the cylinder head.
STRAIGHT EDGE
Measuring the piston ring side clearance. Checking the cylinder block face for distortion.
Engine 59
(5) If the engine is completely dismantled, thor- and not engine or transmission oil, mineral spirits or
oughly clean the cylinder block with solvent and kerosene.
compressed air paying particular attention to the (2) Honing should be carried out by moving the
oilways. Inspect the block for cracks and damage. hone up and down fast enough to obtain a cross hatch
pattern. When hone marks intersect at 60 degrees, the
TO CHECK PISTON CLEARANCE pattern is most satisfactory for correct seating of rings.
(1) Using an accurate cylinder measuring gauge, (3) After honing it is necessary that the block be
measure and note the diameter of each bore as cleaned again to remove all traces of abrasives.
previously described. NOTE: When deglazing, the cylinder should
(2) Measure each piston skirt using a microme- be honed only sufficiently to eliminate the
ter as follows: glazed condition. Excessive honing will in-
(a) On 1.6 liter models, measure each piston crease the bore size and alter the piston
skirt at a point 9 mm above the bottom skirt edge and clearance.
at right angles to the gudgeon pin axis.
(b) On 1.8 liter models, measure each piston (4) When honing is complete, ensure that the
skirt at a point 6 mm above the bottom skirt edge and cylinder bore, crankcase area and oilways are thor-
at right angles to the gudgeon pin axis. oughly cleaned.
(3) The difference between the bore and the (5) After the cylinder block has been cleaned and
piston measurement is the piston clearance. If the dried, wipe the bores with a lint free cloth and smear
clearance exceeds the Specifications, renew the pistons them with engine oil to prevent rusting.
and rebore all the cylinders.
(4) Cylinders that have had new pistons installed NOTE: All abrasives must be removed from
or that have been rebored should have the piston the engine components after honing. A so-
clearance checked again. lution of soap and water should be used with
a brush and the components thoroughly
dried. A bore can be considered clean when
it can be wiped clean with a white cloth and
the cloth remains clean. Oil the bores after
cleaning to prevent rusting.
TO FIT NEW PISTON RINGS AND INSTAL
PISTONS
Once the correct piston and the bore relationship
has been determined and the pistons cleaned or
renewed as necessary, proceed as follows:
(1) Place a ring into number one cylinder bore
and using an inverted piston push the ring down 50
mm into the cylinder bore.
(2) Withdraw the piston and measure the gap in
the ring with feeler gauges. Adjust the end gap of the
ring by filing as necessary. See the Specifications for
the ring end gap.
Measuring the piston diameter using a micrometer. On
1.6 liter models, dimension A = 9 mm. On 1.8 liter
models, dimension A - 6 mm.
NOTE: Should the ring end gap be greater cylinder ensure that the front marking on
than the specified gap, another ring set the piston is towards the front of the engine.
should be obtained and the ring end gaps
(10) Turn the crankshaft until number one crank-
checked and compared with the Specifica-
tions. pin is at the bottom of its stroke.
(11) Install number one piston and connecting
(3) Treat each ring and cylinder bore individu- rod
ally and ensure that the rings are assembled to the assembly into its bore. Push the assembly down the
respective piston for the cylinder bore in which they bore until the connecting rod can be aligned with
were installed to check the end gap. number one crankpin.
(4) Assemble each oil control ring to its respec-
tive piston bottom groove as follows: NOTE: The bearing shells should be lubri-
(a) Install the oil ring expander to the cated with engine oil before installation.
piston (12) Install the connecting rod cap and tighten
groove, ensuring that the ends of the expander are the
bulled together and not overlapped. retaining bolts to the specified torque.
(b) Position one end of the lower side rail in the
groove and peel the ring over the piston and into the NOTE: If new bearing shells were installed,
groove. check the bearing clearance with Plastigage
(c) Similarly install the upper side rail. as previously described.
(5) Install the lower compression ring into
the (13) With the bearing clearance as specified, in-
lower piston groove. stal the remaining pistons in the same manner.
(14) Ensure that the crankshaft turns without
NOTE: The compression rings should be binding.
installed with the manufacturers mark fac- (15) With all connecting rod bolts tightened to
ing the top of the piston. To minimize the the specified torque, install the associated
possibility of ring breakage the rings can be components
immersed in hot water prior to installation. by referring to the relevant headings in this section.
(6) Install the upper compression ring into
the
upper piston groove. 11. CRANKSHAFT AND MAIN BEARINGS
(7) Space the compression ring gaps 120 degrees Special Equipment Required:
apart, and ensure that the oil ring gaps and the join in
the oil ring expander are not aligned. To Inspect — Micrometer, Vee blocks, dial gauge
(8) With the rings correctly installed and TO REMOVE
gapped, remove the bearing cap from the connecting
rod. (1) With the engine assembly removed from the
(9) Liberally lubricate the piston assembly and vehicle and the transaxle separated from the engine,
install the piston ring compressor to number one refer to the appropriate headings or sections and
piston. remove the following components: sump, oil pump
pickup pipe, oil pump, and flywheel or drive plate.
NOTE: When installing the pistons to the (2) Remove the crankshaft rear oil seal from the
edge of the bearing cap to cylinder block joint. Install (5) Install the oil seal over the crankshaft. Ensure
the bearing cap bolts and tighten to the specified that the lip of the oil seal faces towards the engine.
torque. (6) Insert the seal as far as possible using finger
(17) Lubricate the l i p of the new oil seal with pressure, and then fully seat the seal using a tubular
lithium grease and carefully install the seal into drift.
position over the crankshaft. Insert the seal as far as (7) Install the remaining components in the
possible using finger pressure and then fully install the re-
sea! using a tubular drift. Ensure that the seal is not verse order of removal, referring to the relevant
damaged during installation and that the seal is headings in this section as necessary.
mounted square to the block face.
(18) Install the remainder of the engine
compo-
nents by referring to the relevant headings in 12. FLYWHEEL/DRIVE PLATE
this
section. Special Equipment Required:
To Renew Ring Gear — Suitable heat source
TO RENEW CRANKSHAFT OIL SEALS
TO REMOVE
Front (1) Remove the transaxle from the vehicle as
(1) Remove the camshaft drive belt as previ- described in the Manual or Automatic Transaxle
ously described. sections, whichever is applicable.
(2) Disconnect the lower radiator hose and drain (2) On manual transaxle models, mark the fly-
the cooling system. wheel and the clutch pressure plate cover to ensure
(3) Select fifth gear on manual transaxle models correct assembly.
and firmly apply the handbrake.
(4) On automatic transaxle models, remove the
torque converter inspection cover to allow access to
the ring gear. Have an assistant hold the ring gear
using a suitable lever.
(5) Remove the crankshaft timing gear retaining
bolt and discard.
(6) Remove the crankshaft timing gear from the
crankshaft. It may be necessary to lever the gear from
the crankshaft using two screwdrivers. Remove the
key and spacer from the crankshaft.
(7) Using a centre punch, tap a small hole in the
front face of the oil seal.
(8) Insert a self tapping screw into the hole.
(9) Remove the seal from the oil pump by
gripping and pulling the end of the screw with a pair
of pliers. View of the drive plate and retaining bolts.
(10) Coat the lip of a new seal with multi-purpose
grease.
(11) Install the oil seal to the oil pump using a Progressively loosen and remove the pressure
tubular drift. Ensure that the lip of the oil seal faces plate retaining bolts.
the inside of the housing. Using a dial gauge, check the runout of the clutch
(12) Install the remaining components in the re- face contacting surface of the flywheel. If the runout
verse order of removal, using a new crankshaft timing exceeds 0.3 mm have the flywheel face surfaced by a
clutch specialist or authorized dealer.
gear retaining bolt and referring to the relevant (3) Suitably mark the flywheel or drive plate so
headings in this section as necessary. that the unit can be installed in the original position
on the crankshaft. Remove the retaining bolts.
Rear (4) Lift the flywheel or drive plate from the
(1) Remove the automatic transaxle or manual engine.
transaxle as described in the appropriate section.
(2) Remove the flywheel/drive plate as described TO CHECK AND INSPECT
under the following heading. Inspect the clutch face contacting surface of the
(3) Lever the oil seal from the rear of the flywheel for cracks or excessive scoring.
crankcase being careful not to damage the crankshaft. (2) Inspect the ring gear teeth for damage, cracks
(4) Coat the lip of a new seal with Lithium or wear. The ring gear on manual transaxle models
grease. can be renewed separately from the flywheel, but on
64 Engine
automatic transaxle models the complete drive plate (4) Check the direction of the chamfered face of
must be renewed. the old ring gear. The new ring gear must be installed
(3) Inspect the drive plate bolt holes for elonga- to the flywheel with the chamfer in the same direction.
tion which is caused by loose retaining bolts. (5) Remove the ring gear, clean the mounting
(4) Inspect the drive plate for cracks. face on the flywheel and remove any burrs.
(5) Repair or renew the flywheel if necessary. (6) Polish a few spots of the ring gear with emery
cloth and heat the ring gear evenly until the polished
TO INSTAL spots turn dark blue.
Installation is a reversal of the removal procedure NOTE; Do not heat the ring gear past the
with attention to the following points: point required to achieve a dark blue color
(1) The flywheel and drive plate retaining bolts or the tempering of the ring gear teeth will
are special micro-encapsulated fasteners.
Install new micro-encapsulated bolts of the be impaired.
correct (7) With the flywheel suitably supported, pick
strength classification on assembly. the ring gear up using pliers, and place it evenly onto
(2) Thoroughly clean the crankshaft threads with the flywheel. Use a hammer and a brass drift to ensure
a thread tap. Clean the threads with solvent and dry that the ring gear seats against the flywheel flange.
before installing the flywheel or drive plate retaining
bolts. NOTE: Allow the ring gear to cool slowly.
(3) Tighten the flywheel or drive plate retaining Do not quench it in water.
bolts to the specified torque and on manual transaxle
models, align the clutch plate as described in the
Clutch section. 13. ENGINE MOUNTINGS
TO RENEW FLYWHEEL RING GEAR TO RENEW LEFT HAND SIDE MOUNTING
(1) With the flywheel removed from the vehicle, (1) Disconnect the positive and negative battery
drill a 6 mm diameter hole between two teeth of the terminals, loosen the battery clamp nuts and withdraw
ring gear. the battery from the engine compartment.
NOTE: Do not drill right through the ring (2) Remove the bolts retaining the battery car-
gear as this will damage the flange on the rier to the inner mudguard and remove the battery
flywheel. carrier and associated components from the engine
compartment.
(2) Secure the flywheel, with the drilled hole (3) Support the transaxle using a jack. Interpose
uppermost in a soft jawed vice. a block of wood between the head of the jack and the
(3) Place a cold chisel above the hole in the ring transaxle to prevent damage to the transaxle.
gear and hit it sharply to split the ring gear.
(4) Hold the nut and remove the mounting (6) If necessary, remove the nuts and bolts
through bolt. retaining the support brackets to the engine assembly
(5) Remove the bolts retaining the mounting to and withdraw the support brackets.
the transaxle and maneuver the mounting from the Installation is a reversal of the removal procedure
engine compartment. ensuring that the weight of the engine is bearing on
(6) If necessary remove the bolts retaining the the engine mounting before tightening the through
support bracket to the inner mudguard and withdraw bolt securely.
the support bracket.
Installation is a reversal of the removal procedure TO RENEW FRONT TORQUE DAMPER
ensuring that the weight of the engine is bearing on (1) Raise the front of the vehicle, remove the
the engine mounting before tightening the through splash guard fasteners and remove the splash guard(s)
bolt securely. from the front of the vehicle.
(2) Remove the through bolts and nuts from the
TO RENEW RIGHT HAND SIDE MOUNTING torque damper.
(1) Disconnect the negative battery terminal. NOTE: It may be necessary to unclip the
(2) On 1.8 liter models, remove the air cleaner wiring harness from the lower radiator sup-
assembly. Refer to the Fuel and Engine Management port panel to gain access to the front through
section if necessary. bolt.
(3) Support the engine under the sump using a
jack. Interpose a block of wood between the head of
the jack and the sump to prevent damage.
(4) Hold the nut and remove the mounting
through bolt and rubber.
(5) Remove the bolts retaining the mounting to
the inner mudguard and maneuver the mounting
from the engine compartment.
Underbody view of the exhaust system. Underbody view of the tailpipe and muffler.
Engine 67
(6) Carefully inspect the exhaust system and (1) Install all components and check the system
discard any components which are cracked, worn or for correct positioning before tightening the retaining
corroded. Inspect the catalytic converter as described bolts and nuts.
in the Emission Control Section. (2) Ensure that the catalytic converter is in-
Installation is a reversal of the removal procedure stalled in the correct direction as indicated on the
with attention to the following points: housing.
68
SPECIFICATIONS renew the heater core. Check the hose clips and hoses
and renew if necessary.
Coolant capacity ........................................ 6.0 liters (4) Leaks at the thermostat cover and/or water
Thermostat: pump O rings. Renew the O rings.
Opening temperature........................... 91 deg (5) Worn or damaged water pump seal assembly:
C Renew the water pump.
Fully open temperature .................... 103 deg (6) Worn or damaged water pump bearing as-
C sembly: Renew the water pump.
Cooling fan: (7) Loose or rusted welch plugs; Renew the
Fan cut in temperature ....................... 100 deg C welch plugs.
Fan cut out temperature ...................... 95 deg C (8) Faulty cylinder head gasket or loose cylinder
Radiator cap opening head bolts: Renew the cylinder head gasket and
pressure ................................................... 78 -98 kPa correctly tighten the cylinder head bolts.
(9) External crack in the cylinder head or cylin-
TORQUE WRENCH SETTINGS der block: Repair or renew the faulty components.
Water pump retaining bolts .............................25 Nm NOTE: Check the system for external leak-
Thermostat housing bolts.................................15 Nm age by running the engine to operating
Sender unit .......................................................10 Nm temperature over a dry floor and checking
for the leak source.
Check the vehicle interior below the
heater core for moisture. If a rusted welch
1. COOLING SYSTEM TROUBLE SHOOTING plug is found, it is a good practice to renew
all the welch plugs.
COOLANT LEAKAGE - EXTERNAL
COOLANT LEAKAGE - INTERNAL
(1) Loose hose clips or faulty hoses: Tighten the
hose clips or renew the faulty water hoses. ( 1 ) Cylinder head gasket leak due to warped
(2) Leaking radiator core or tanks: Repair or cylinder head or cylinder block gasket faces: Reface
renew the radiator.
(3) Leaking heater core or hoses: Repair or
the cylinder head or cylinder block and renew the (7) Loss of coolant from the overflow: Check
cylinder head gasket. and rectify as described under the heading Coolant
(2) Crack in the cylinder head or cylinder block: Loss By Overflow.
Repair or renew as necessary. (8) Poor circulation: Check and rectify as de-
NOTE; Check the engine for internal leak- scribed under the heading Coolant Circulation Faulty.
age by withdrawing the dipstick and inspect- (9) Low engine oil level: Stop the engine imme-
ing for emulsified oil. Run the engine and diately and replenish the oil in the sump.
check for excessive steam at the exhaust (10) Restricted muffler, catalytic converter or
pipe which would indicate coolant leakage damaged tailpipe, accompanied by loss of power:
into the combustion chamber. Remove the restrictions or renew the faulty com-
ponents as necessary.
COOLANT LOSS BY OVERFLOW (11) Incorrectly adjusted or dragging brakes:
Check and rectify by adjustment or renewal of
(1) Overfull system: Drain the excess coolant components.
from the system.
(2) Faulty radiator cap: Renew the faulty cap. (12) Faulty temperature gauge and/or sender unit:
(3) Blocked radiator core tubes: Clean or renew Check and rectify as necessary.
the radiator core. NOTE: Engine overheating is indicated by
(4) Faulty thermostat: Renew the thermostat. an excessive rise in engine temperature
(5) Coolant foaming due to poor quality anti- shown by the temperature gauge.
freeze or corrosion inhibitor: Drain the system and Overheating is usually accompanied by
renew the coolant and additive. steam emitting from the coolant overflow
pipe and loss of engine power. A blown
cylinder head gasket may be indicated by
bubbles in the coolant.
COOLANT CIRCULATION FAULTY
(1) Partial blockage of the radiator core tubes:
reverse flush or renew the radiator core.
(2) Sludge deposits in the engine water jacket:
Clean and flush the engine water jacket and add
inhibitor to the coolant.
(3) Faulty water pump: Renew the water pump.
(4) Faulty thermostat: Renew the thermostat.
(5) Collapsing lower radiator hose: Renew the
lower radiator hose and check the radiator core tubes.
(6) Insufficient coolant in the system: Replenish
the coolant and check for leaks.
NOTE: If rust or sludge deposits are sus-
Renew the radiator cap if the sealing rubber has pected, check the color of the coolant in the
deteriorated.
radiator. Rusty or muddy coolant indicates
rust or sludge in the system.
ENGINE OVERHEATING
(1) Radiator cap defective: Renew the radiator 2. HEATER AND AIR CONDITIONER
cap. TROUBLE SHOOTING
(2) Incorrect fuel mixture: Check the fuel system
as described in the Fuel and Engine Management NO HOT AIR INSIDE VEHICLE
section. Faulty thermostat: Renew the thermostat.
(3) Obstructed air passage through the radiator (1) Faulty heater valve: Check and renew the
core from the front to the rear: Blow the obstruction (2)
from the rear to the front of the radiator core using valve. Blocked heater hoses: Remove the blockage.
compressed air or water pressure. (3) Blocked heater core: Clean or renew the core.
(4) Faulty thermostat: Renew the thermostat. (4)
(5) Incorrect ignition timing: Check and adjust NOTE: Ensure that the engine is reaching
the ignition timing as described in the Engine Tune-up normal operating temperature. If in doubt
section. check the operation of the thermostat as
(6) Incorrect valve timing: Set the valve timing described under the Thermostat heading in
as described in the Engine section. this section.
70 Cooling and Heating Systems
TO DRAIN AND REFILL (8) Using a clean container, mix Nissan long life
coolant with clean soft water to the proportions
(1) Place a drain tin under the radiator drain stipulated on the coolant container.
plug. (9) Slowly pour the premixed coolant into the
(2) Switch the heater controls to the maximum radiator until the radiator is full and all air has
heat position. escaped through the temperature sender switch hole.
(3) Remove the radiator cap and open the Install the radiator cap.
radiator drain plug. (10) Fill the coolant reserve tank to the Maxi-
(4) Disconnect the reserve tank hose from the mum mark.
radiator filler neck. (11) Start the engine and allow it to idle.
(5) Lower the end of the hose and drain the (12) When coolant starts to flow through the
coolant from the reserve tank. temperature sender switch hole, install the temperature
(6) After all the coolant has drained from the sender switch and tighten securely.
cooling system, install the radiator drain plug (13) Continue idling the engine until the cooling
ensuring fan is activated.
that the plug seal is in good condition. (14) Switch the engine off and allow it to cool.
(7) Disconnect the wire from the temperature (15) Refill the radiator using coolant and install
sender switch and remove the switch using a suitable the radiator cap.
spanner.
Dismantled view of the radiator and associated components. Automatic transaxle model with
air conditioning.
72 Cooling and Heating Systems
5. COOLING FAN
1. To Battery
2. Fusible link COLOUR CODE
3. Fusible link B - Black
4. Fusible link L - Blue
5. Ignition relay Y - Yellow
6. Fuse 20 amp W - White
7. Cooling fan relay O - Orange
8. Cooling fan
9. Coolant temperature
sensor
10. To air conditioning
fan relay
11. To throttle position
sensor
12. Control unit
NOTE: Refer to the Fuel and Engine Man- (f) Switch the ignition Off. disconnect the
agement section for the correct procedure for cooling fan wiring connector at the radiator and
backprobing the control unit. connect power to the fan. Renew the fan if it does not
(3) In operation (1) if the cooling fan is station- run.
ary proceed as follows: (4) On air conditioned models, remove the
(a) Connect a jumper lead between the terminals jumper lead from the ALDL connector if still in-
A and B of the diagnostic link connector. stalled, start the engine and allow it to idle. Switch the
(b) if the fan runs, the fan circuit is satisfactory. air conditioning on and ensure that the cooling fan
If the engine is overheating check the coolant temper- runs.
ature sensor as described in the Fuel and Engine If the cooling fan is operating as described above
Management section under the appropriate codes. but cooling system problems still exist, refer to the
(c) If the fan does not run, check the fuse (6) and Trouble Shooting heading at the start of this section.
the fusible link (4) shown on the illustration.
(d) Backprobe terminal C1 at the electronic TO REMOVE AND INSTAL COOLING FAN
control unit using an LED test lamp connected to the
positive battery terminal. If no circuit exists, renew (1) Disconnect the negative battery terminal.
the electronic control unit. (2) Disconnect the cooling fan and, if applicable,
(e) If the fuse and fusible links are serviceable, the air conditioning fan wiring connectors at the
ensure that power is available at the white and pink upper edge of the radiator.
wires from the fuse and fusible link of the cooling fan (3) On models with air conditioning, remove the
relay. Repair any faults in the wiring to that point if compressor hose bracket bolt from the centre of the
necessary. radiator support panel.
Dismantled view of the fans and the shroud assembly. Air conditioned model.
Cooling and Heating Systems 75
(4) Remove the bolts retaining the fan shroud Installation is a reversal of the removal procedure
assembly to the radiator and carefully move the with attention to the following points:
shroud assembly upwards and towards the engine to (1) Ensure that all sealing surfaces are clean.
release it from the lower mountings. (2) Renew the O ring on installation.
(3) Tighten the thermostat cover retaining bolts
NOTE: On models with air conditioning, it securely.
will be necessary to hold the air conditioning (4) Fill the cooling system as previously de-
compressor hoses towards the engine to scribed ensuring that the heater control lever is in the
allow clearance for removal of the shroud maximum heat position. Check for coolant leaks.
assembly.
(5) If necessary, remove the fan from the fan TO CHECK
motor by removing the retaining bolts or on some NOTE: A visual examination of the thermo-
models the nut and washers. stat will often determine its serviceability
(6) If necessary, remove the fan motor from the and make further testing unnecessary. For
shroud assembly by removing the retaining bolts or instance, a thermostat with its valve fully-
nuts. open when removed from a cold engine is
Installation is a reversal of the removal procedure
with attention to the following points: obviously faulty and should be renewed.
(1) Ensure all the fan motor and fan retaining Remove the thermostat from the thermostat
nuts and bolts are tightened securely.
(2) Ensure that all the rubber mountings are in
good condition.
6. THERMOSTAT
Special Equipment Required:
To Check — Thermometer
TO REMOVE AND INSTAL
(1) Drain the cooling system as previously de-
scribed under the Radiator heading.
(2) On 1.6 liter models, remove the air cleaner
assembly. Refer to the Fuel and Engine Management
section if necessary.
(3) Disconnect the top radiator hose from the
thermostat cover.
(4) Remove the bolts retaining the thermostat
cover to the thermostat housing.
(5) Remove the thermostat cover, thermostat
and O ring from the thermostat housing.
NOTE: The thermostat and cover are ser-
viced as a unit and cannot be renewed
separately.
These openings are plugged with welch plugs. The (6) Lightly smear the edge of a new welch plug
plugs may have to be renewed when cleaning the and the opening with Loctite 675.
engine water jackets or when defective due to corro- (7) Place the welch plug onto the opening and
sion. using a tube or socket fitting the rim of the plug, drive
the plug squarely into its opening.
TO RENEW
NOTE; The welch plug must be driven into
NOTE: If a welch plug is found to be the opening straight and squarely or leaks
corroded it is good policy to renew all the may occur.
welch plugs. (8) Install the components which were removed
(1) Drain the radiator and cylinder block. to gain access to the plug.
(2) Remove the necessary engine components or (9) Fill the cooling system as previously de-
accessories to gain ample working space around the scribed. With the reserve tank pressure cap installed,
welch plug. run the engine until it reaches normal operating
(3) Using a punch and hammer, tap the welch temperature and check for coolant leaks.
plug on its outer circumference into its opening.
(4) Grasp the edge of the welch plug with a pair 10. HEATER UNIT, WATER VALVE AND
of multi-grip pliers and using the shoulder of the pliers CONTROLS
as a fulcrum, lever the plug out of its opening.
(5) Thoroughly clean and dry the welch plug DESCRIPTION
opening.
The heater controls use four adjustments to direct
air through the vehicle.
The air intake control selects fresh air from
outside the vehicle or recirculates air from inside the
vehicle. The recirculate position is used in dusty
conditions or to rapidly heat or cool the vehicle
interior. The fresh air position is the best to deodorize
the vehicle interior or demist the windscreen.
The air control lever is used to direct air to the
face outlets, the floor outlets and the windscreen
outlets. This control also has two bi-level positions
where air may be directed to the face and floor outlets
or the windscreen and floor outlets.
The temperature control opens or shuts the heater
water valve to control the flow of engine coolant
through the heater core, which raises or lowers the
temperature of the air passing through the core.
Tap the welch plug on its outer circumference into the
Maximum heating is only available when the engine is
cylinder block.
at the normal operating temperature.
The fan speed control switches the fan on and off
and is used to select the desired fan speed.
Air conditioned models use identical controls
with the addition of an air conditioner on/off button.
The centre of the button is illuminated when the air
conditioner is switched on.
Using a correct fitting tube or socket, drive the welch View of the heater controls.
plug into its opening.
78 Cooling and Heating Systems
The air conditioner operates only when the engine (4) Remove the steering column upper mount-
is running as the compressor is belt driven from the ing bolts.
engine. (5) Remove the steering column cross support
Operating the air conditioner with the tempera- bolts and move the support towards the right hand
ture control raised to a hot setting will produce side of the vehicle.
dehumidified hot air which is particularly useful for (6) Remove the centre support retaining bolts
demisting the vehicle glass. and remove the centre support from the vehicle.
Maximum cooling is achieved by operating the air (7) Remove the demister duct and the right
conditioner with the temperature control lowered hand side ventilator duct from the vehicle.
fully to the coldest setting. Operate the fan at high (8) Disconnect the blower fan wiring connector
speed when using the coldest temperature setting to from the rear of the heater controls.
avoid forming ice on the evaporator. (9) Remove the heater retaining bolts.
(10) On models with air conditioning, it will be
necessary to loosen the evaporator mounting bolts.
TO REMOVE AND INSTAL HEATER UNIT (11) Working in the engine compartment, push
(1) Remove the dashboard as described in the the heater pipe grommet through the bulkhead.
Body section. (12) Maneuver the heater unit upwards slightly
(2) Drain the cooling system as previously de- and out from the bulkhead using care not to damage
scribed in this section. the heater pipes.
(3) Loosen the hose clamps and disconnect the (13) To remove the heater core and tap assembly,
heater hoses from the heater pipes. remove the screws from the retaining strap and slide
the heater core from the heater unit.
NOTE: If the heater hoses will not come off
the heater pipes, do not use excess force or Installation is a reversal of the removal procedure
the heater core retaining strap will be dam- with attention to the following points:
aged. Cut the hoses from the heater pipes. (1) Before installing the heater unit to the
View of the heater unit with the dashboard, centre support, demister duct and right hand ventilator
duct removed.
Cooling and Heating Systems 79
NUT j-
continuous stream of bubbles indicates that the refriger- tenance other than the following. Where applicable,
ant charge is low. refer to the Lubrication and Maintenance section for
A large number of bubbles or foam indicates that the recommended service intervals.
the refrigerant charge is very low. (1) Check the refrigerant charge level in the
No bubbles or the presence of oil streaks in the receiver/dryer sight glass. Recharge the system as
sight glass indicate that the system is completely necessary. It is considered normal for the system to
empty. require periodic recharging.
NOTE: If the outside air temperature is (2) Inspect the air conditioner pipes and hoses
high, a certain number of bubbles may be for leaks, deterioration and alignment. Evidence of oil
observed in the sight glass, even though the leakage is an indication of refrigerant leakage. Repair
system is fully charged. or renew as necessary.
(3) Inspect the evaporator drain tube and the
If the system requires recharging, the vehicle condenser cooling fins for blockage. Clean as neces-
should be taken to an authorized dealer for evacu- sary.
ation, leak testing and recharging. (4) Check the drive belt for deterioration and for
Do not operate the system if it is known that the correct tension. Refer to the Engine Tune-up section
refrigerant charge is low as damage may result. for the correct procedure.
MAINTENANCE (5) Operate the system at least once a week for
approximately 15 minutes to keep the compressor
The air conditioning system requires little main- seals lubricated.
82
ADJUSTMENTS
Base idle speed ..................................... 550-650 rpm
Ignition timing.......................................... 10° BTDC
TORQUE WRENCH SETTINGS
Throttle body nuts .......................................... 10 Nm
*Throttle body bolts ........................................ 12 Nm
*Fuel hose fittings............................................ 35 Nm
Fuel rail bolts ....................................................8 Nm
Fuel tank drain plug........................................ 24 Nm
Coolant temperature sensor ............................ 12 Nm
Oxygen sensor.................................................. 40 Nm
MAT sensor..................................................... 14 Nm Check that the MAP sensor hose is not blocked or split
*1.6 liter engine and ensure that all electrical connections are clean and
l . 8 liter engine secure.
Fuel and Engine Management 83
Check the distributor cap for cracks or tracking be- The air filter element should be renewed at 40 000 km
tween the terminals. intervals. 1.8 liter engine.
Fuel and Engine Management
(4) MAP sensor faulty or supply hose discon- (4) Leaks in the fuel supply system: Check the
nected or blocked: Check the vacuum supply hose. connections and components for leakage.
Check the operation of the MAP sensor. (5) Leaking fuel injector(s): Clean or renew the
faulty injector(s).
EXCESSIVE FUEL CONSUMPTION (6) Engine operating temperature too low:
(1) Blocked air cleaner element: Check the ele- Check the thermostat and electric cooling fan as
ment and clean or renew as necessary. described in the Cooling and Heating Systems section.
(2) Incorrect fuel pressure: Check the fuel pump
and fuel pressure regulator. 2. DESCRIPTION
(3) Faulty coolant temperature sensor: Check
the connections and operation. The engine management system on the range of
vehicles covered by this manual controls the opera-
tion of the ignition system and the fuel system.
The central component of the engine management
system is the electronic control unit (ECU). The con-
trol unit is a micro-computer which controls the igni-
tion timing and the amount of fuel injected according
to signals received from various sensors. As changes
are detected in engine load and speed, coolant tem-
perature, barometric pressure, air temperature (1.8
liter engine), throttle position and vehicle speed, the
control unit alters the ignition timing and the fuel
injection amount to achieve optimum engine effi-
ciency.
The control unit incorporates a self diagnosis
mode which stores and displays codes relating to
certain system malfunctions. Whenever power is sup-
plied to the control unit, the control unit performs a
Ensure that all fuel connections are securely tightened.
View of the 1.8 liter engine showing the engine management components.
Fuel and Engine Management 85
View of the 1.6 liter engine showing the engine management components.
Air cleaner removed for clarity.
series of tests on various components in the system mixture then enters the combustion chamber via the
and records the results, If a fault is discovered, the inlet valves.
ECM warning lamp on the instrument cluster will On 1.6 liter engines, the fuel is injected by a single
illuminate while the engine is running. When the self injector, located above the throttle valve within the
diagnosis mode is activated, the ECM warning lamp throttle body assembly. The injector fires twice per
will flash codes indicating the area in which the fault engine revolution under most operating conditions.
has occurred. On 1.8 liter engines, four injectors are used. The
This function is very useful in locating system fuel is distributed to the injectors via the fuel rail. All
faults, particularly intermittent problems. However, injectors fire simultaneously once per engine revolu-
the self diagnosis mode does not provide comprehen- tion under most operating conditions.
sive testing of the EFI system, and therefore should Under conditions of high load the control unit
always be used in conjunction with the other test may signal the injector(s) to fire more often. However,
procedures described later in this section in order to if the engine speed exceeds 6 700 rpm the control unit
accurately locate system faults. will cease firing the injectors until the engine speed is
The high energy electronic ignition system con- below 6 200 rpm.
sists of a distributor and an ignition coil. Fuel is supplied under pressure by an electric fuel
The distributor has two functions. The first is to pump mounted in the fuel tank and the pressure is
produce and distribute secondary high tension voltage regulated by a pressure regulator.
to the spark plugs. On 1.6 liter engines, the regulator consists of a
The second function is to provide the control unit spring tensioned diaphragm which is mounted to the
with information on engine speed and crankshaft side of the throttle body assembly. The fuel pressure is
position. regulated by the tension of the spring against the
The ignition timing is constantly adjusted by the diaphragm, opening and closing the fuel return port.
control unit to suit varying engine and vehicle oper- On 1.8 liter engines, the pressure regulator is
ating conditions. mounted adjacent to the fuel rail and consists of a
In the fuel injection system, a metered amount of diaphragm with fuel pressure acting on one side and
fuel is sprayed into the air stream. The air/fuel spring tension and manifold vacuum acting on the
86 Fuel and Engine Management
other. The fuel pressure is maintained at a constant lights and ignition system analysers are not
pressure relevant to the manifold vacuum. A dispos- compatible with this engine management
able paper element fuel filter is mounted on the engine system and may result in incorrect readings.
bulkhead. It is therefore recommended that the man-
The amount of fuel injected is relevant to the time ufacturer of the lest equipment be consulted
the injector remains open. The basic time the injector before proceeding to use the equipment.
remains open is governed by the control unit which If a test procedure requires the use of a
uses information from the various sensors to give test lamp or voltmeter, ensure that only the
optimum engine efficiency for given conditions. specified instrument is used to prevent mis-
The idle air control (IAC) valve controls the fast leading diagnosis.
idle speed during engine warm up and maintains the
basic idle speed at a set value by compensating for MULTIMETER
loads such as air conditioning or the selection of Drive
on automatic transaxle models. It is essential that in all tests where voltage or
The throttle body assembly is mounted to the resistance is to be measured, a digital display multi-
inlet manifold and controls the amount of air entering meter with a minimum 10 megohms impedance be
the engine by the action of the throttle valve. used.
Efficient operation of the EFI system depends on
accurate signals being received by the control unit and
controlled air flow beyond the throttle valve. There-
fore it is essential that all air, fuel and electrical
connections be clean and tight.
BR K
The procedure for fabricating an LED test lamp is tem, the diagnosis and testing procedures
fully described in the Electrical System section. described in this section should not be
If a conventional test lamp with a filament type carried out by persons lacking an under-
bulb is to be used, ensure that the current draw of the standing of electronics and the precautions
test lamp does not exceed 0.3 amp to avoid damage to associated with the servicing of electronic
the electronic components. components. It is recommended that should
To check the current draw connect an accurate a fault arise in the system, the vehicle be
ammeter, such as the multimeter described previ- referred to an authorized workshop.
ously, in series with the test lamp and a battery. The control unit can be damaged by
If the ammeter reads less than 0.3 amp the test component faults not indicated by the self
lamp is suitable. diagnosis codes and the renewal of the
control unit without locating the cause of
Tachometer the failure will result in the failure of the
replacement unit. It is for this reason that
(1) Disconnect the resistor from the tachometer the practice of substituting components to
pick-up wiring connector which is located on the isolate faults is not recommended.
ignition coil wiring harness, and connect the positive Prior to performing any of the follow-
lead of an accurate tachometer to the brown wire ing operations, refer to the Service Pre-
terminal in the wiring connector. cautions and Procedures heading.
(2) Connect the negative lead to a good earthing
point. PRELIMINARY CHECKS
Prior to performing the Self Diagnosis Test Pro-
cedures, perform the following preliminary checks and
rectify any problems as necessary.
(1) Check for an adequate supply of fuel in the
fuel tank.
(2) Check the wiring connectors and earth points
of all engine management components for clean,
secure connections. To prevent damage to the control
unit, disconnect the negative battery terminal before
disconnecting any engine management wiring connec-
tors.
(3) Check the condition of the battery. Refer to
the Electrical System section for checking procedures.
Rectify any faults as necessary.
(4) Check the air cleaner element for restriction.
View showing the location of the tachometer pickup
wiring connector with the resistor installed.
(5) Check for air leaks at the throttle body, inlet
manifold and all related hoses.
Timing Light (6) Check the fuel pump pressure as described
later in this section.
(1) Connect the timing light to the engine fol- (7) Ensure that the engine is in a satisfactory
lowing the instrument manufacturers instructions. mechanical condition and is in tune. Refer to the
Engine and Engine Tune-up sections as necessary.
NOTE: Do not connect or disconnect the
timing light with the engine running as
voltage surges could damage the alternator SELF DIAGNOSIS
or control unit. Do not allow the high This function is very useful in locating system
tension leads to open circuit with the engine faults particularly intermittent problems. However,
running as damage to the engine manage- the self diagnosis mode does not provide comprehen-
ment system could result. sive testing of the engine management system, and
(2) Do not connect the timing light positive lead therefore should always be used in conjunction with
to the alternator output terminal. Where possible, the other test procedures described later, in order to
connect the power leads of the timing light to an accurately locate system faults.
external power source to prevent possible transient
voltages damaging the alternator or control unit. To Interpret Self Diagnosis Codes
4. SYSTEM DIAGNOSIS AND ADJUSTMENTS Once the self diagnosis mode is activated, various
fault codes will be displayed as a series of flashes by
NOTE: Due to the use of complex electronic the ECM warning lamp on the instrument cluster.
components in the engine management sys-
90 Fuel and Engine Management
To identify the code number, count the number of heading, perform the circuit test procedure and rectify
times the ECM warning lamp flashes. Each fault code the cause of the code before proceeding.
comprises two groups of flashes separated by a 1.2 If the ECM warning lamp flashes codes other than
second pause. The first group represents tens and the code 55, check the wiring harness between the diag-
second group represents single units. For example 1 nostic link connector terminal B and the control unit
flash followed by a 1.2 second pause followed by 4 wiring connector terminal A9 for shorts. Repair or
flashes would be code number 14. Similarly 4 flashes renew the wiring harness as necessary.
followed by a 1.2 second pause followed by 2 flashes If no fault can be found, renew the control unit.
would be code number 42. If the ECM warning lamp does not illuminate,
proceed as follows:
The code will be displayed three times. If more (a) Check the METER fuse located in the fuse
than one fault code is present, the self diagnosis panel adjacent to the steering column and the fusible
system will indicate each one in numerical order, with links located in the fusible link connecting block at the
a 3.2 second pause between each code, and then rear of the battery. Renew the fuse or fusible links as
repeat the sequence. necessary.
The fault codes can be identified as follows: (b) Check the wiring harness to the instrument
cluster. Repair or renew the harness.
CODE NUMBER FAULT AREA (c) Check the Check Engine lamp bulb. Renew if
12 Satisfactory operation necessary.
13 Oxygen sensor open circuit (d) Check the EGI relay. Renew as necessary.
14 Coolant temperature sensor (3) Connect a jumper lead across terminals A
circuit (voltage low) and B on the diagnostic link connector located under
15 Coolant temperature sensor the front passengers seat above the control unit.
circuit (voltage high) (4) Note the codes indicated by the flashing
21 Throttle position sensor circuit ECM warning lamp.
(voltage high) If code 12 is displayed, the system is operating
22 Throttle position sensor circuit correctly.
(voltage low) If codes other than code 12 are displayed, refer to
23 MAT sensor circuit the component or circuit test procedure under the
(voltage' high) 1.8 liter engine appropriate heading as indicated by the code number.
only If more than one code is being displayed, test each
24 Vehicle speed sensor circuit indicated fault working in the order of display of the
25 MAT sensor circuit code numbers.
(voltage low) 1.8 liter engine (5) After completing the self diagnosis test pro-
only cedure, remove the jumper lead from the diagnostic
33 MAP sensor circuit link connector.
(voltage high) (6) After repairing or renewing the necessary
34 MAP sensor circuit
(voltage low)
42 Electronic spark timing circuit
44 Oxygen sensor circuit
(lean exhaust)
45 Oxygen sensor circuit
(rich exhaust)
51 Mem-Cal
55 Control unit input circuits
Test Procedure
(1) Perform the following checks:
(a) Ensure that the battery voltage is above 11
volts.
(b) Ensure that the throttle valve is fully closed.
(c) Place the transaxle in neutral.
(d) Ensure that the air conditioner, fan, tights
and all other accessories are switched off. View showing the location of the diagnostic link
(2) Turn the ignition On and confirm that the connector. Passengers seat removed for clarity.
ECM warning lamp on the instrument cluster is Inset shows the diagnostic link connector terminal
illuminated but not flashing. identification.
If code 55 is displayed, refer to the Control Unit
Fuel and Engine Management 91
components, erase the self diagnosis memory as adjustable. The throttle stop screw controls
described under the following heading. the base idle speed and is factory set. The
(7) Repeat the self diagnosis test procedure and following base idle speed adjustment should
ensure that code 12 is displayed. only be performed if the throttle body has
been renewed, or if comprehensive testing of
To Erase Memory related components indicates that adjust-
ment is required.
(1) With the ignition Off, remove the fusible link
that is positioned third from the front of the fusible (1) Before adjusting the base idle speed perform
link connecting block located at the rear of the the following tests;
battery. (a) Check the spark plug gaps, the high tension
(2) Install the fusible link after 10 seconds. leads and the ignition timing as described previously
in the Engine Tune-up section.
(b) Check the air inlet system for leaks between
the throttle body and inlet manifold and the inlet
manifold and cylinder head.
NOTE; Any vacuum leaks will make the
engine idle faster than it should.
(c) Check that all wiring connectors and vacuum
hoses are securely connected.
(d) Ensure that the transaxle is in Park or
Neutral.
(e) Ensure that the air cleaner element is service-
able.
(2) On 1.6 liter engines, remove the air cleaner
assembly, disconnect the vacuum hose from the
throttle body and seal the vacuum hose fitting.
(3) Ensure that the throttle valve moves freely
and returns to the fully closed position when slowly
released.
(4) Connect an accurate tachometer to the en-
View showing the location of the fusible links. gine as previously described under the Service Pre-
cautions and Procedures heading.
TO CHECK AND ADJUST IGNITION TIMING (5) Start the engine and allow the engine to
warm up and the idle rpm to stabilize. Check that all
(1) Connect a timing light to the engine as electrical accessories and the air conditioning, if
previously described under the Service Precautions equipped, are turned off.
and Procedures heading. (6) With the engine idling in Park or Neutral,
(2) Start the engine and allow it to reach normal slowly disconnect the brake servo unit vacuum supply
operating temperature. hose from the inlet manifold. Allow the engine to run
(3) Connect a jumper lead between terminals A for one minute.
and B on the diagnostic link connector.
(4) With the engine idling at the specified speed,
check the ignition timing with the timing light.
The timing mark on the crankshaft pulley should
be aligned with the pointer on the inner liming belt
cover.
(5) If necessary, loosen the distributor body
retaining nuts and turn the distributor until the timing
marks are aligned.
(6) Tighten the distributor body retaining nuts
and check that the timing is correct.
(7) Remove the jumper lead from the diagnostic
link connector and disconnect the timing light from
the engine.
TO ADJUST BASE IDLE SPEED
NOTE: The idle speed is controlled by the Location of the base idle adjusting screw. 1.8 liter
idle air control (IAC) valve and is not engine.
92 Fuel and Engine Management
Installed view of the throttle body assembly showing When depressurizing the fuel system, remove the rear
the location of the base idle adjusting screw. 1.6 liter seat cushion and disconnect the fuel pump wiring
engine. connector.
(7) Disconnect the IAC valve wiring connector (3) Start and run the engine until it stalls.
and slowly connect the vacuum supply hose to the Operate the starter motor for 10 seconds to ensure
inlet manifold. Allow five seconds to elapse and note that the pressure has dissipated.
the engine speed. (4) Connect the fuel pump wiring connector and
(8) If the engine speed is not to Specifications, install the rear seat cushion.
remove the plug from the throttle body housing on 1.6
liter engines, or the cap from the base idle adjusting NOTE: Failure to depressurize the fuel sys-
screw on 1.8 liter engines, and adjust the idle screw tem when instructed may result in a fuel
until the engine speed is 625 rpm. spray and possible fire.
(9) Stop the engine and connect the IAC valve
wiring connector. TO TEST FOR EXTERNAL LEAKS
(10) On 1.8 liter engines, install a new cap to (1) Connect a jumper lead between terminals G
the and H on the diagnostic link connector.
base idle adjusting screw. (2) Switch the ignition On.
On 1.6 liter engines, seal the throttle stop screw (3) Check for leaks at all hose connections and
with silicone sealant and install the air cleaner assem- joints between the fuel pump and the engine.
bly. (4) Switch the ignition Off and remove the
(11) Erase the memory codes as previously de- jumper lead from the diagnostic link connector.
scribed. (5) If renewal of a component is necessary,
(12) Start the engine and increase the speed to depressurize the fuel system as previously described.
3 000 rpm for 10 seconds to allow the idle air control (6) Use only hoses and clamps as specified by
valve to reset. the manufacturer.
liter engines, or the throttle body hose fitting on 1.6 If the fuel pressure is less than 270 kPa on 1.8 liter
liter engines. engines or 90 kPa on 1.6 liter engines, renew the fuel
(5) Tighten all connectors securely. Check for pump.
external leaks as previously described. If the fuel pressure is more than previously
(6) Start the engine and note the pressure while specified, renew the pressure regulator assembly on
the engine is idling. 1.8 liter engines or the pressure regulator diaphragm
(7) Switch the engine Off and check that the on 1.6 liter engines.
residual pressure does not decrease. (9) If the fuel pressure in operation (6) is above
If the fuel pressure is within Specifications and Specifications, proceed as follows:
does not decrease, the fuel system is in a serviceable (a) On 1.8 liter engines, disconnect the fuel
condition. Depressurize the fuel system and discon- return hose from the pressure regulator outlet.
nect the pressure gauge. On 1.6 liter engines, disconnect the fuel return
If the fuel pressure is above Specifications proceed hose from the front throttle body hose fitting.
to operation (9). (b) Connect a suitable length of fuel hose to the
If the fuel pressure is below Specifications proceed pressure regulator or the front throttle body hose
to the following operation. filling and place the opposite end of the hose into a
If the fuel pressure decreases, an internal leak is petroleum resistant container.
indicated. Proceed to the following heading and carry (c) Connect a jumper lead between terminals G
out the test procedure. and H on the diagnostic link connector and switch the
ignition On.
If the fuel pressure is 230-270 kPa on 1.8 liter
engines or 62-90 kPa on 1.6 liter engines, locate and
remove the restriction in the fuel return hose or pipe.
If the fuel pressure is more than previously
specified, renew the pressure regulator assembly on
1.8 liter engines or the pressure regulator diaphragm
on 1.6 liter engines.
FUEL FILTER
To Remove and Install
Refer to the Engine Tune-up section for the
procedure to remove and install the fuel filter.
FUEL PUMP
To Test Electrical Circuit
Refer to the EGI and Fuel Pump Relays heading
later in this section for the test procedures.
To Remove and Install
(1) Depressurize the fuel system as previously
described.
(2) Disconnect the negative battery terminal. View of the fuel pump cover plate removed, showing
(3) Remove the rear seat backrest as described the fuel pump installed.
under the Seats heading in the Body section. Installation is a reversal of the removal procedure
(4) Remove the bolts securing the fuel pump with attention to the following points:
cover plate to the floor panel, remove the rubber (1) Ensure that a new fuel pump O ring seal is
grommet and slide the cover plate from the wiring installed.
harness. (2) Tighten the fuel pump retaining screws and
(5) Mark the fuel hoses to ensure correct install- the fuel hose clamps securely.
lation and disconnect the hoses from the fuel pump. (3) Ensure that the rubber grommet is seated
(6) Remove the fuel pump retaining screws and correctly in the fuel pump cover plate.
carefully remove the fuel pump from the fuel tank. (4) Install the fuel pump cover plate ensuring
that the arrow on the plate is facing the front of the
vehicle.
(5) Connect the negative battery terminal, start
the engine and test for leaks as previously described.
Rectify as necessary.
FUEL PRESSURE REGULATOR
To Remove and Install — 1.8 Liter Engine
(1) Depressurize the fuel system as previously
described.
(2) Disconnect the negative battery terminal.
View of the fuel pump assembly removed from the fuel Installed view of the fuel pressure regulator. 1.8 liter
tank. engine.
Fuel and Engine Management 95
terminal D16 on 1.6 liter engines, or D15 and D16 (5) Install the fuel rail retaining bolts and tighten
on to the specified torque.
1.8 liter engines. (6) Install the fuel hoses to the fuel rail
The test lamp should light. and
If the test lamp does not light check the wiring tighten the hose clamps securely.
harness for continuity between the injector wiring (7) Check for fuel leaks as previously described.
connector(s) and the control unit wiring connector
terminals. To Remove and Install Injector — 1.6 Liter Engine
Repair or renew the wiring harness as necessary.
(1) Depressurize the fuel system as previously
To Remove and Install Injectors and Fuel Rail — 1.8 described.
Liter Engine. (2) Disconnect the negative battery terminal.
(3) Remove the air cleaner assembly. If neces-
(1) Depressurize the fuel system as previously sary refer to the heading Air Cleaner Assembly in this
described. section.
(2) Disconnect the negative battery terminal. (4) Remove the injector retaining plate screw
(3) Thoroughly clean around the injectors and and remove the injector retaining plate from the
throttle body assembly.
(5) Insert the blade of a screwdriver from the
front of the throttle body assembly under the rim of
the injector in which the retaining plate locates.
Support the screwdriver on a suitable object to act as
a fulcrum.
(6) Carefully lever the screwdriver until the
injector can be withdrawn from the throttle body
assembly.
(7) Remove and discard the upper and lower O
View of the fuel rail, injectors and pressure regulator ring seals from the injector. If necessary remove the
removed from the engine. lower filter screen from the injector.
the fuel rail to prevent foreign material entering the NOTE: As the injector contains electrical
engine.
(4) Suitably mark the fuel hoses, loosen the hose
clamps and disconnect the fuel hoses from the fuel
rail.
(5) Disconnect the vacuum hose from the fuel
pressure regulator.
(6) Loosen the hose clamp and disconnect the
engine ventilation hose from the throttle body.
(7) Remove the bolts securing the fuel rail and
injectors to the inlet manifold.
(8) Carefully raise the fuel rail and injectors
from the inlet manifold until the injector nozzles are
clear of the manifold.
(9) Disconnect each injector wiring connector by
pushing in the wire retaining clip.
(10) Using a small screwdriver, remove the injec-
tor retaining clip and withdraw the injectors from the
fuel rail.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Check the condition of the injector O ring
seals and renew if necessary.
(2) Install the injectors to the fuel rail and secure
with the retaining clips.
(3) Connect the wiring connectors to each injec-
tor ensuring that the wire clip is locked in position.
(4) Install the injectors to the inlet manifold,
carefully guiding the injectors into place ensuring that View of the fuel injector removed from the throttle
the O ring seals are not damaged. body assembly. 1.6 liter engine.
Fuel and Engine Management 97
circuitry do not immerse it in cleaning the fuel meter assembly. Remove and discard the
solvent as this may result in irreparable gasket.
damage. (5) If necessary, remove the fuel pressure regu-
Installation is a reversal of the removal procedure lator as previously described.
with attention to the following points: Installation is a reversal to the removal procedure
(1) Lubricate the new O ring seals with auto- with attention to the following points;
matic transmission fluid prior to installing them to the (1) If removed, install the fuel pressure
injector. If removed, ensure that the lower filter screen regulator
is installed. as previously described.
(2) Firmly push the injector into the throttle (2) Place a new gasket on the throttle body,
body assembly until it is fully seated, ensuring that the aligning the holes in the gasket with those in the
injector connection terminals face towards the rear of throttle body, ensuring that the idle air passage is not
the vehicle. blocked.
(3) Apply Loctite 262 to the injector retaining (3) Coat the fuel meter assembly retaining
plate screw and tighten securely. screws with Loctite 262 and tighten securely.
(4) Start the engine and check for fuel leaks as (4) Install the fuel meter assembly retaining bolts
previously described. and tighten to the specified torque.
(5) Install the air cleaner and tighten the retain- (5) Connect the fuel supply and return hoses and
ing nuts securely. tighten the clamps securely.
(6) Install the injector as previously described.
(7) Start the engine and check for fuel leaks.
FUEL METER ASSEMBLY - 1.6 LITRE Rectify as necessary.
ENGINE (8) Install the air cleaner assembly.
To Remove and Install
(1) Remove the injector as previously described. FUEL TANK
(2) Mark the fuel supply and return hoses, To Remove and Install
release the clamps and disconnect the hoses from the (1) Depressurize the fuel system as previously
fuel meter assembly. described.
(3) Remove the air cleaner assembly base gasket (2) Disconnect the negative battery terminal.
from the fuel meter assembly. (3) Remove the fuel pump cover plate retaining
(4) Remove the bolts and screws securing the screws, disconnect the wiring harness rubber grommet
fuel meter assembly to the throttle body and remove from the cover plate and remove the cover plate from
the wiring harness.
(4) Raise the rear of the vehicle and support it
on chassis stands. Refer to the Wheels and Tires
section if necessary.
(5) Remove the fuel tank drain plug and drain
the fuel into a petroleum resistant container.
(6) Mark the fuel hoses and disconnect the hoses
from the fuel pump.
(7) Disconnect the hoses from the fuel filler neck
pipe, the fuel check valve and the fuel tank breather
pipe.
(8) Remove the bolts retaining the intermediate (2) Release the air intake hose retaining clamps,
exhaust pipe to the rear of the catalytic converter, disconnect the hose from the air cleaner upper
remove the bolt securing the exhaust mounting to the housing and the throttle body and remove the hose.
underbody and slightly lower the intermediate exhaust (3) Remove the screw securing the air cleaner
pipe. Support the intermediate pipe to prevent the intake duct to the front panel mounting bracket.
tailpipe fouling the lower bumper panel. (4) Remove the hexagon head screws retaining
(9) Remove the bolts retaining the stabilizer bar the air cleaner mounting bracket to the right hand
mounting brackets to the underbody and allow the inner mudguard and remove the air cleaner from the
stabilizer bar to drop. engine compartment.
(10) Remove the bolts retaining the exhaust heat (5) Release the upper housing retaining clips,
shield to the underbody, located at the front of the separate the upper housing from the lower housing
fuel tank. and remove the element.
(11) Remove the handbrake cable mounting (6) Remove the air cleaner intake duct retaining
bracket retaining nuts and remove the mounting screw and disconnect the duct from the lower air
brackets from the mounting studs. cleaner housing.
(12) Remove the fuel tank retaining bolts and (7) If necessary, remove the bolts securing the
maneuver the fuel tank from the vehicle. mounting bracket to the air cleaner lower housing and
Installation is a reversal of the removal procedure separate the mounting bracket from the housing.
with attention to the following points: (8) Thoroughly clean the upper and lower hous-
(1) When installing the fuel tank, ensure that the ings in cleaning solvent and check for cracks, splits or
fuel pump wiring harness is directed through the damage that would allow unfiltered air to enter the
aperture in the floor. engine. Renew any components as necessary.
(2) Install the stabilizer bar mounting Installation is a reversal of the removal procedure
bracket with attention to the following points:
bolts and tighten to the specified torque. Refer to the (1) Ensure that the rubber insulators are in-
Rear Suspension section.
(3) Using a new gasket, install the intermediate
exhaust pipe to the catalytic converter ensuring that
the earth wire terminal is installed and tighten the
bolts securely.
(4) Connect the fuel filler neck hose, the fuel
check valve hose and the breather hose ensuring that
they are secured firmly.
(5) Tighten the fuel tank drain plug to the
specified torque.
(6) Connect the fuel hoses to the fuel pump,
using the marks made during removal to ensure
correct installation.
(7) Install the fuel pump wiring harness and the
rubber grommet to the fuel pump cover plate. Install
the cover plate and tighten the retaining bolts se-
curely.
(8) Connect the fuel pump wiring connector
securely.
(9) Check for fuel leaks as previously described.
6. AIR FLOW COMPONENTS
NOTE: Before proceeding with any of the
operations in this section, refer to the Ser-
vice Precautions and Procedures heading.
AIR CLEANER ASSEMBLY
To Renew Element
The procedure for renewing the air cleaner ele-
ment is covered in the Engine Tune-up section.
To Remove and Install — 1.8 Liter Engine Dismantled view of the air cleaner assembly. 1.8 liter
(1) Disconnect the negative battery terminal. engine.
Fuel and Engine Management 99
stalled on each side of the air cleaner mounting THROTTLE BODY ASSEMBLY
bracket when installing the mounting bolts. To Remove and Install — 1.8 Liter Engine
(2) If renewing the element, ensure that the
specified element is installed and is correctly seated in (1) Disconnect the negative battery terminal.
the air cleaner housing. (2) Release the air intake hose clamp and dis-
(3) Ensure that the air intake hose clamps are connect the air intake hose from the throttle body.
tightened securely. (3) Unclip the actuating rod from the throttle
lever using a small screwdriver under the ball socket if
To Remove and Install — 1.6 Liter Engine necessary.
(1) Disconnect the negative battery terminal. (4) Mark the throttle body vacuum hoses with
(2) Remove the nuts and washers retaining the quick drying paint or similar and disconnect the hoses
air cleaner to the throttle body assembly. from the throttle body. Disconnect the engine vent
(3) Release the top cover retaining clips and hose from the throttle body.
remove the top cover and the air cleaner element. (5) Disconnect the wiring connectors from the
Remove the air cleaner retainer from the throttle body throttle position sensor and the IAC valve.
bolts. (6) Remove the retaining nuts and withdraw the
(4) Disconnect the engine vent hose from the air throttle body and gasket.
cleaner support clamp.
(5) Slightly raise the air cleaner and tilt it
towards the windscreen. Disconnect the engine vent
hose and the temperature sensor vacuum hose from
the underside of the air cleaner.
(6) Remove the air cleaner housing from the
engine.
Installation is a reversal of the removal procedure disconnect the inner throttle cable from the throttle
with attention to the following points: linkage.
(1) Ensure that all throttle body passages are (9) Remove the bolts retaining the throttle body
clean. Blow out with compressed air if necessary. assembly to the inlet manifold and remove the
(2) Install the throttle body to the inlet assembly and the gasket from the engine.
manifold (10) If necessary remove the retaining screws and
using a new gasket and tighten the retaining nuts to remove the fuel meter assembly, the IAC valve and
the specified torque. the throttle position sensor from the throttle body
(3) Connect the vacuum hoses to the throttle assembly.
body in the positions previously marked. Installation is a reversal of the removal procedure
with attention to the following points:
(4) Clip the actuating rod to the throttle body (1) If removed, install the fuel meter assembly,
lever. Check the dimensions shown in the illustration the throttle position sensor and the IAC valve as
and adjust the rod length if necessary. described under the relevant headings.
(5) Check the adjustment of the throttle cable as (2) Install the throttle body assembly to the inlet
described later in this section. manifold using a new gasket and tighten the retaining
(6) Connect the air intake hose and tighten the bolts to the specified torque.
hose clamps securely. (3) Connect the vacuum hoses to the throttle
body using the marks made on removal to ensure
To Remove and Install — 1.6 Liter Engine correct installation.
(1) Depressurize the fuel system as previously (4) On automatic transaxle models, connect the
described. kickdown actuating rod to the throttle linkage.
(2) Disconnect the negative battery terminal. (5) Install the throttle cable and check the adjust-
(3) Remove the air cleaner assembly and base ment as described later in this section.
gasket as previously described.
(4) Mark the fuel supply and return hoses, INLET MANIFOLD
release the clamps and disconnect the hoses from the To Remove and Install
throttle body assembly.
(5) Disconnect the injector, throttle position To remove and install the inlet manifold, refer to
sensor and the IAC valve wiring connectors. Remove the relevant heading in the Engine section.
the injector wiring harness from the throttle body
assembly and place it to one side. IDLE AIR CONTROL (IAC) VALVE
(6) Mark and disconnect the vacuum hoses from To Test
the throttle body assembly.
(7) On automatic transaxle models, disconnect (1) Connect an accurate tachometer to the en-
the kickdown actuating rod from the throttle linkage. gine.
(8) Slide the outer throttle cable from the (2) With the engine at normal operating temper-
mounting bracket, rotate the throttle linkage and ature and all accessories switched Off, note the idle
speed.
(3) With the ignition switched Off, disconnect
the IAC valve wiring connector.
(4) Start the engine and check the idle speed.
If the idle speed is the same as that noted in
operation (2) proceed to operation (7).
If the idle speed is higher than noted in operation
(2) proceed as follows.
(5) With the ignition switched Off, connect the
IAC valve wiring connector.
(6) Start the engine and check the idle speed.
If the idle speed is not the same as that noted in
operation (2) proceed to operation (7).
If the idle speed is the same as noted in operation
(2) the IAC valve is operating correctly. However, if
the engine is not idling correctly carry out the
following checks.
(a) Check the air inlet system for vacuum leaks.
NOTE: Any vacuum leak will cause a fast
idle.
View of the throttle body assembly showing the loca-
tion of the base idle adjusting screw. 1.8 liter engine.
Fuel and Engine Management 101
(10) Remove the jumper lead from the MAP If no fault is found, check the vacuum supply hose
sensor wiring connector and measure the voltage for restriction, leakage or correct installation.
across terminals A and C on the MAP sensor wiring
connector. To Remove and Install
If the voltage is below 4 volts, proceed to opera-
tion (12). (1) Disconnect the negative battery terminal.
If the voltage is 4-6 volts, proceed as follows. (2) Disconnect the MAP sensor wiring connec-
(11) With the ignition switched Off, disconnect tor and the vacuum hose.
the wiring connectors from the control unit and check (3) Remove the retaining screws and remove the
the wiring harness for continuity and shorts between MAP sensor from the vehicle.
MAP sensor wiring connector terminal B and control Installation is a reversal of the removal procedure
unit wiring connector terminal C11. Check the wiring with attention to the following points:
connectors for faults. Repair or renew the wiring (1) If a new MAP sensor is to be installed ensure
harness as necessary. that the colored insert inside the connector cavity
If no fault is found, renew the control unit and matches the color of the wiring connector.
retest for fault codes. (2) Ensure that the wiring connector and the
(12) Disconnect the wiring connector from the vacuum hose are connected securely.
throttle position sensor.
(13) Measure the voltage across terminals A and THROTTLE CABLE
C on the MAP sensor wiring connector.
If the voltage is 4-6 volts, renew the throttle To Remove and Install
position sensor as described later in this section. (1) On 1.6 liter engines, remove the air cleaner
If the voltage is below 4 volts, proceed as follows. assembly as previously described.
(14) With the ignition switched Off, disconnect (2) Slide the outer throttle cable from the
the wiring connectors from the control unit and check mounting bracket, rotate the throttle linkage and
the wiring harness for continuity and shorts between disconnect the inner throttle cable from the throttle
the MAP sensor wiring connector terminal C and linkage.
control unit wiring connector terminal C14. Check the (3) Disconnect the throttle cable from the retain-
wiring connectors. Repair or renew the wiring harness ing clamps in the engine compartment.
as necessary. (4) Disconnect the plastic retainer from the top
If no fault is found, renew the control unit and of the throttle pedal and disengage the inner throttle
retest for fault codes. cable from the pedal.
(15) Test the MAP sensor as follows: (5) Remove the bolts securing the throttle cable
(a) With the ignition switched On and the MAP to the bulkhead and withdraw the throttle cable.
sensor wiring connector connected, measure the volt- Installation is a reversal of the removal procedure.
age across terminals A and B by backprobing the
MAP sensor wiring connector. The voltage should be To Adjust
as follows:
(1) On 1.6 liter engines, remove the air cleaner
ALTITUDE VOLTAGE assembly as previously described.
(2) Remove the snap ring securing the outer
Below 305 m ..........................................3.8-5.5 volts throttle cable to the insulator in the mounting bracket.
305-610 m .............................................3.6-5.3 volts
610-914 m .............................................3.5-5.1 volts
914-1 219 m..........................................3.3-5.0 volts
1 219-1 524 m ......................................3.2-4.8 volts
1 524-1 829 m ......................................3.0-4.6 volts
1 829-2 133 m ......................................2.9-4.5 volts
2 133-2 438 m.......................................2.8-4.3 volts
2 438-2 743 m ......................................2.6-4.2 volts
2 743-3 048 m ......................................2.5-4.0 volts
If the voltage is not as specified, renew the MAP
sensor.
(b) If the voltage is as specified, apply a 34 kPa
vacuum to the MAP sensor using a vacuum pump.
The voltage should be 1.2-2.3 volts lower than that
measured in operation (a).
If the voltage is not as specified, renew the MAP
sensor. View showing the throttle cable adjustment point. 1.8
liter engine.
104 Fuel and Engine Management
on the pickup coil wiring connector. The resistance To Remove and Install
should be 500-1 500 ohms.
If the resistance is not as specified in either of the (1) Disconnect the negative battery terminal.
above tests, renew the pickup coil. (2) Disconnect the grey wiring connector and the
(4) Remove the retaining spring from the dis- black wiring connector from the ignition coil in that
tributor drive coupling. order. Disconnect the high tension lead.
(5) Using a pin punch, remove the drive pin (3) Remove the coil mounting bracket retaining
from the shaft. bolts and remove the coil and bracket from the
(6) Remove the drive coupling, washer, tang engine.
washer and thrust spring from the shaft. Installation is a reversal of the removal procedure.
(7) Remove the rotor and shaft from the distrib-
utor housing. ELECTRONIC SPARK TIMING
(8) Remove the retainer from the distributor To Test - Code 42
housing and withdraw the pickup coil. (1) Erase the self diagnosis code memory as
(9) Remove the retaining screws and remove the previously described.
control module from the distributor body. (2) Start and run the engine at idle speed for 60
(10) Carefully lever the stationary pole from the seconds or until the ECM warning lamp lights.
housing using a suitable screwdriver.
Assembly is a reversal of the dismantling proce- (3) Stop the engine, switch the ignition On and
dure with attention to the following points: connect a jumper lead between terminals A and B on
(1) Ensure that the mating surfaces of the dis- the diagnostic link connector. Note any fault codes
tributor housing and the control module are clean. displayed.
(2) Apply a silicone heat sink compound to the If code 42 is displayed, proceed to operation (4).
surfaces between the control module and the distrib- If code 42 is not displayed, but was displayed
utor housing. when the self diagnosis test procedure was originally
performed, an intermittent fault is indicated. Proceed
IGNITION COIL as follows:
To Test (a) Check for faulty wiring connections. Check
that all wiring connectors are clean and secure.
(1) Disconnect the grey wiring connector and the (b) Check that all earth wires are secure.
black wiring connector from the ignition coil in that (4) With the ignition switched Off, disconnect
order. the control unit wiring connectors.
(2) Measure the resistance between coil terminal (5) With the ignition switched On, measure the
I and the coil body. There should be a high resistance. resistance between the control unit wiring connector
(3) Measure the resistance between coil termi- terminal D4 and a good earthing point. The resistance
nals 2 and 4. There should be a low resistance. should be less than 500 ohms.
(4) Measure the resistance between coil terminal If the ohmmeter reading is as specified, check the
3 and the high tension terminal. The resistance should wiring harness between the distributor 4 pin wiring
be other than infinity. connector terminal D and the control unit wiring
If any of the tests indicate a fault, renew the connector terminal D4 for continuity. Repair or
ignition coil. renew the wiring harness as necessary. Also ensure
that the distributor 4 pin wiring connector is making
good contact when connected to the distributor.
If no fault can be found, renew the ignition
control module.
If the resistance is as specified proceed as follows.
(6) With the lead of a test lamp connected to the
positive battery terminal, backprobe the control unit
wiring connector terminal D5.
If the test lamp does not light, proceed to
operation (7).
If the test lamp lights, disconnect the 4 pin wiring
connector from the distributor. If the test lamp
remains illuminated check the wiring harness between
the distributor 4 pin wiring connector terminal B and
the control unit wiring connector terminal D5 for
shorts to earth. Repair or renew the wiring harness as
necessary. If the test lamp extinguishes, renew the
Installed view of the ignition coil showing the coil ignition system control module.
terminal identification. (7) Connect an ohmmeter between the control
Fuel and Engine Management 107
unit wiring connector terminal D4 and a good earth- If code 55 is displayed, an intermittent fault is
ing point. indicated. Switch Off the engine, erase the self diag-
(8) With the lead of a test lamp connected to the nosis codes and run the engine for 2 minutes. Return
positive battery terminal, backprobe the control unit to operation (1) and repeat the test procedures.
wiring connector terminal D5. As the test lamp probe If code 55 continues to return, renew the control
touches the terminal, the ohmmeter reading should unit.
change from less than 500 ohms to over 5 000 ohms.
If the ohmmeter reading is not as specified, To Remove and Install
proceed to operation (9).
If the ohmmeter reading is as specified, switch the (1) Disconnect the negative battery terminal.
ignition Off and install the control unit wiring connec- (2) Slide the passengers front seat to the rear-
tors. Run the engine for 60 seconds or until the ECM most position and working under the seat, disconnect
warning lamp lights and check for fault codes. the control unit wiring connectors.
If code 42 is displayed renew the control unit. (3) Disengage the plastic control unit cover from
If code 42 is not displayed, check the wiring the mounting plate and remove the control unit from
harness for continuity or shorts between the control the vehicle.
unit wiring connector terminals D4 and D5 and the (4) If necessary, remove the screws retaining the
distributor 4 pin wiring connector terminals D and B. Mem-Cal cover to the control unit.
(9) Disconnect the 4 pin wiring connector from (5) Release the Mem-Cal unit retaining clips,
the distributor. grasp the Mem-Cal unit at each end and remove it
(10) Check for continuity between the control
unit wiring connector terminal D4 and a good earth- from the control unit.
ing point. There should be no continuity. Installation is a reversal of the removal procedure
If the continuity is not as specified, check the with attention to the following points:
wiring harness between the distributor 4 pin wiring (1) When installing the Mem-Cal unit, align the
connector terminal D and the control unit wiring notches in the Mem-Cal with those in the control unit
connector terminal D4 for shorts to earth. Repair or and push on each end of the Mem-Cal unit. Do not
renew the wiring harness as necessary. push on the middle section of the Mem-Cal unit.
If the continuity is as specified, check the wiring
harness between the distributor 4 pin wiring connec-
tor terminal B and the control unit wiring connector
terminal D5 for continuity. Repair or renew the
wiring harness as necessary. If no fault is found, renew
the ignition system control module.
CONTROL UNIT
To Test Input Circuits — Code 55
(1) Switch the ignition On with the engine
stopped and note the ECM warning lamp.
(2) If a steady light is showing, proceed to
operation (3).
If code 55 is displayed, proceed as follows:
(a) Switch the ignition Off and disconnect the
wiring connector from the control unit.
(b) Switch the ignition On and measure the
voltage at the wiring connector on terminals C10,
CI1, C12, C13 and A9. Disregard terminal C12 on
1.6 liter engines.
(c) If there is voltage at any of the terminals
tested above, a faulty wiring harness is indicated.
Repair the short circuit to voltage and return to
operation (1).
(d) If there is no voltage at any of the terminals
tested, a faulty control unit is indicated. Renew the
control unit and return to operation (1).
(3) Connect a jumper lead between terminals A
and B on the diagnostic link connector and note if
code 55 is displayed. View of the control unit with the Mem-Cal unit re-
moved.
108 Fuel and Engine Management
originally performed, an intermittent fault is indi- Installation is a reversal of the removal procedure
cated. Proceed as follows: with attention to the following points;
(a) Check for faulty wiring connections. Check (1) Apply Loctite 675 or a similar conductive
that all wiring connectors are clean and secure. sealer to the threads of the sensor. Tighten the sensor
(b) Check that all earth wires are secure. to the specified torque.
(4) Disconnect the wiring connector from the (2) Fill the cooling system with the correct
coolant temperature sensor. mixture of water and inhibitor as described in the
(5) With the ignition switched On, measure the Cooling and Heating Systems section.
voltage across the terminals on the coolant tempera- (3) Ensure that the wiring connector is clean and
ture sensor wiring connector. The voltage should be secure.
4-6 volts.
If the voltage is below 4 volts, proceed to opera- THROTTLE POSITION SENSOR
tion (9). To Test - Codes 21 and 22
If the voltage is as specified, proceed as follows.
(6) Remove the coolant temperature sensor NOTE: The following test procedure as-
from the vehicle. sumes that fault codes 21 or 22 have been
(7) Connect an ohmmeter to the coolant temper- displayed during the self diagnosis test pro-
ature sensor terminals. cedure. If no codes have been displayed but
(8) Immerse the meta1 end of the coolant the operation of the throttle position sensor
tem- is suspect, begin the test procedure at oper-
perature sensor in a 50/50 mixture of glycol and iced ation (24).
water at a temperature of 0 deg C. The resistance
should be 6 000 ohms. (1) Erase the self diagnosis code memory as
Slowly heat the mixture and measure the resis- previously described.
tance of the coolant temperature sensor at the follow- (2) Start and run the engine at idle speed for 60
ing temperatures. Compare the results with the spec- seconds or until the ECM warning lamp lights.
ified values: If the engine will not start, disconnect the throttle
position sensor wiring connector and proceed to
0 degC................................................. 6 000 ohms operation (8). .
20 deg C.................................................. 2 500 ohms (3) With the engine idling, quickly increase the
30 deg C.................................................. 1 800 ohms engine speed to 3 000 rpm and return to idle.
40 deg C.................................................. 1 200 ohms If the ECM warning lamp remains illuminated,
70 deg C.......................................................450 ohms proceed to operation (4).
90 degC .......................................................250 ohms If the ECM warning lamp extinguishes, an inter-
100 deg C.....................................................190 ohms mittent fault is indicated. Proceed as follows:
110 deg C.....................................................110 ohms (a) Check for faulty wiring connections. Check
that all wiring connectors are clean and secure.
If the resistances obtained are not as specified at (b) Check that all earth wires are secure.
any of the given temperatures, renew the coolant (4) Stop the engine, switch the ignition On and
temperature sensor and retest for fault codes. connect a jumper lead between terminals A and B on
(9) Disconnect the control unit wiring connec- the diagnostic link connector. Note any fault codes
tors. displayed.
(10) Check the wiring harness for shorts and If codes 21 or 22 are displayed, proceed as
continuity between the coolant temperature sensor follows.
wiring connector terminals and the control unit wiring (5) Remove the jumper lead from the diagnostic
connector terminals C10 and D2. Repair or renew the link connector.
wiring harness as necessary. (6) Erase the self diagnosis codes as previously
Also check the control unit terminals for damage. described.
If no fault is found, renew the control unit and (7) Disconnect the wiring connector from the
retest for fault codes. throttle position sensor.
If code 22 was displayed in operation (4), proceed
To Remove and Install to operation (13).
If code 21 was displayed in operation (4), proceed
(1) Disconnect the negative battery terminal. as follows.
(2) Disconnect the wiring connector from the (8) Start and run the engine at idle speed for 2
coolant temperature sensor. minutes or until the ECM warning lamp lights. If the
(3) Drain the coolant as described in the Cooling engine will not start, proceed to operation (11).
and Heating Systems section to a level below the (9) Stop the engine, switch the ignition On and
sensor. connect a jumper lead between terminals A and B on
(4) Unscrew the sensor from the thermostat
housing.
Fuel and Engine Management 111
If the voltage does not increase as specified, renew If codes 23 or 25 are not displayed but were
the throttle position sensor. displayed when the self diagnosis test procedure was
If the voltage is as specified, proceed as follows. originally performed, an intermittent fault is indi-
(28) With the ignition switched On and the cated. Proceed as follows:
throttle valve held fully open, measure the voltage at (a) Check for faulty wiring connections. Check
control unit wiring connector terminal C13. The that all wiring connectors are clean and secure.
voltage should be above 4 volts. (b) Check that all earth wires are secure.
If the voltage is below 4 volts, renew the throttle (4) Disconnect the wiring connector from the
position sensor. MAT sensor.
(5) With the ignition switched On, measure the
To Remove and Install voltage across the terminals on the MAT sensor wiring
connector. The voltage should be 4-6 volts.
(1) Disconnect the negative battery terminal. If the voltage is below 4 volts, proceed to opera-
(2) On 1.6 liter engines, remove the air cleaner tion (9).
assembly as previously described. If the voltage is as specified, proceed as follows.
(3) Disconnect the throttle position sensor wir- (6) Remove the MAT sensor from the engine.
ing connector. (7) Connect an ohmmeter to the MAT sensor
(4) Remove the throttle position sensor retain- terminals.
ing screws and remove the throttle position sensor (8) Immerse the metal end of the MAT sensor in
from the throttle body. a container of iced water at a temperature of 4 deg C.
Installation is a reversal of the removal procedure The resistance should be 7 500 ohms.
with attention to the following points: Slowly heat the water and measure the resistance
(1) Ensure that the throttle valve is in the fully of the MAT sensor at the following temperatures.
closed position. Compare the results with the specified values:
(2) Tighten the retaining screws securely and
install the wiring connector. 20 deg C.................................................. 3 400 ohms
38 deg C....................................................1 800 ohms
70 degC...................................................... 450 ohms
100 deg C.................................................... 185 ohms
If the resistances obtained are not close to the
specified figures at any of the given temperatures,
renew the MAT sensor and retest for fault codes.
(9) Disconnect the control unit wiring connec-
tors.
(10) Check the wiring harness between the MAT
sensor wiring connector and the control unit wiring
connector terminals C12 and A11 for shorts and
continuity. Also check the control unit terminals for
damage.
Repair or renew the wiring harness as necessary.
If no fault is found, renew the control unit and
retest for fault codes.
View of the throttle position sensor removed from the
throttle body assembly. To Remove and Install
MANIFOLD AIR TEMPERATURE (MAT) (1) Disconnect the negative battery terminal.
SENSOR - 1.8 LITRE ENGINE
To Test - Codes 23 and 25
(1) Erase the self diagnosis code memory as
previously described.
(2) Start and run the engine for 2 minutes or
until the ECM warning lamp lights.
(3) Stop the engine, switch the ignition On and
connect a jumper lead between terminals A and B on
the diagnostic link connector. Note any fault codes
displayed.
If codes 23 or 25 are displayed, proceed to
operation (4). Installed view of the MAT sensor. 1.8 liter engine.
Fuel and Engine Management 113
(2) Disconnect the wiring connector from the (c) If no fault is found in (a) and (b) renew the
MAT sensor. control unit and retest for fault codes.
(3) Unscrew the sensor from the inlet manifold. (7) Check the wiring harness earth circuit be-
Installation is a reversal of the removal procedure tween the control unit wiring connector D6 and the
with attention to the following points: right rear cylinder head bolts. Repair or renew the
(1) Apply Loctite 567 or a similar conductive wiring harness as necessary.
sealer to the threads of the sensor. Tighten the sensor If no fault is found, thoroughly check the oxygen
to the specified torque. sensor connector. If the connector is not faulty, renew
(2) Ensure that the wiring connector is clean and the oxygen sensor.
tight.
To Test - Code 44
OXYGEN SENSOR (1) Run the engine until normal operating tem-
To Test - Code 13 perature is attained.
(2) With the ignition switched Off, connect a
(1) Run the engine until the normal operating jumper lead between terminals A and B on the
temperature is obtained. diagnostic link connector.
(2) With the ignition switched Off, connect a (3) Start and run the engine at approximately
jumper lead between terminals A and B on the 1 600-1 800 rpm for 2 minutes and note the ECM
diagnostic link connector. warning lamp.
(3) Start and run the engine at approximately If the ECM warning lamp is off more than on or
1 600-1 800 rpm for 2 minutes and note the ECM flashes at the rate of twice per second, proceed to
warning lamp. operation (4).
If the ECM warning lamp flashes at the rate of If the ECM warning lamp flashes evenly at the
twice per second, proceed to operation (5). rate of once per second an intermittent fault is
If the ECM warning lamp flashes at the rate of indicated. Proceed as follows:
once per second or slower, proceed as follows. (a) Check for faulty wiring connections. Check
(4) Remove the jumper lead from the diagnostic that all wiring connectors are clean and secure.
link connector and run the engine above 2 000 rpm (b) Check that all earth wires are secure.
for 2 minutes, noting the ECM warning lamp. (4) Switch the engine Off and disconnect the
If the ECM warning lamp lights, stop the engine, oxygen sensor wiring connector.
switch the ignition On and connect a jumper lead (5) Start and run the engine at 1 600-1 800 rpm
between terminals A and B on the diagnostic link for at least 30 seconds and note the ECM warning
connector. If code 13 is displayed proceed to opera- lamp.
tion (5). If the ECM warning lamp flashes at the rate of
If the ECM warning lamp does not light, an twice per second proceed to operation (6).
intermittent fault is indicated. Proceed as follows: If the ECM warning lamp extinguishes for at least
(a) Check for faulty wiring connections. Check 30 seconds, check the wiring harness between the
that all wiring connectors are clean and secure. oxygen sensor wiring connector and the control unit
(b) Check that all earth wires are secure. wiring connector terminal D7 for shorts to earth.
(5) Switch the ignition Off and disconnect the Repair or renew the wiring harness as necessary.
oxygen sensor wiring connector. Using a jumper lead If no fault can be found in the wiring harness, renew
connect the oxygen sensor wiring connector to a the control unit.
suitable engine earth.
(6) Start and run the engine at approximately
1 600-1 800 rpm and note the ECM warning lamp.
The lamp may flash for a few seconds but should then
extinguish for at least 30 seconds.
If the ECM warning lamp functions as described,
proceed to operation (7).
If the ECM warning lamp does not function as
described proceed as follows:
(a) Check the wiring harness between the oxygen
sensor wiring connector and the control unit wiring
connector D7 for open circuits. Repair or renew the
wiring harness as necessary.
{b) Check the earth circuit between the control
unit wiring connect D6 and the right rear cylinder
head bolts. Repair or renew the wiring harness as
necessary. Installed view of the oxygen sensor.
114 Fuel and Engine Management
(6) Check the vehicle for the following: (d) Charcoal canister purge system blocked or
(a) Low fuel pressure. restricted.
(b) Contaminated fuel. (e) Faulty coolant temperature sensor circuit.
(c) Vacuum leaks at the inlet manifold, engine (f) Faulty MAT sensor circuit (1.8 liter engine).
vacuum hoses and engine ventilation hoses. (g) MAP sensor operation.
(d) Exhaust manifold leaks before the oxygen (h) Throttle position sensor operation.
sensor. If the above items have been checked and no
(e) Correct MAP sensor operation. faults have been found, a faulty oxygen sensor is
(f) Blocked oxygen sensor metal vent cover eg.
plugged with mud etc. indicated.
(g) Fuel injectors) partially blocked. Refer to a Renew the oxygen sensor, run the engine and
fuel injection specialist or a Nissan dealer. ensure that no fault codes are set.
If the above items have been checked and no
faults have been found, a faulty oxygen sensor is To Remove and Install
indicated. Renew the oxygen sensor, run the engine (1) If the engine is cold, run the engine for
and ensure that no fault codes are set. approximately two minutes to allow easy oxygen
sensor removal.
To Test — Code 45 (2) Disconnect the negative battery terminal and
(1) Run the engine until normal operating tem- the oxygen sensor connector.
perature is attained.
(2) With the ignition switched Off, connect a
jumper lead between terminals B and A on the
diagnostic link connector.
(3) Start and run the engine at approximately
1 600-1 800 rpm for 2 minutes and note the ECM
warning lamp.
If the ECM warning lamp is on more than off or
flashes at the rate of twice per second, proceed to the
following operation.
If the ECM warning lamp flashes evenly at the
rate of once per second an intermittent fault is View of the oxygen sensor removed from the exhaust
indicated. Proceed as follows: manifold.
(a) Check for faulty wiring connections. Check
that all wiring connectors are clean and secure. (3) Remove the exhaust manifold heat shield
(b) Check that all earth wires are secure. retaining bolts and remove the heat shield from the
(4) Switch the engine Off and disconnect the engine.
oxygen sensor wiring connector. (4) Remove the oxygen sensor with a short ring
(5) Using a jumper lead, connect the oxygen spanner using care not to damage the sensor wire.
sensor wiring connector to a suitable engine earth. Installation is a reversal of the removal procedure
(6) Start and run the engine at 1 600-1 800 rpm with attention to the following points:
and note the ECM warning lamp. (1) When installing a sensor that has previously
If the ECM warning lamp extinguishes for at least been removed, coat the sensor threads with anti-seize
30 seconds, proceed to operation (7). compound. Nissan recommend a mixture of liquid
If the ECM warning lamp flashes on more than off graphite and glass beads.
or flashes at the rate of twice per second, switch the (2) Install the sensor and tighten to the specified
engine Off and disconnect the control unit wiring torque.
connectors. Using an ohmmeter, check that there is no (3) Connect the electrical connector ensuring
resistance between the control unit wiring connector that the wiring is secured away from the exhaust.
terminal D6 and earth. Repair or renew the wiring as (4) Install the heat shield and tighten the retain-
necessary. ing bolts securely.
If no fault can be found in the wiring harness, On 1.6 liter engines, ensure that the hot air inlet
renew the control unit. tube is located correctly between the heat shield and
the air cleaner housing.
NOTE: The wiring harness for terminal D6 (5) Start the engine and check for leaks.
earths through the right hand rear cylinder
head bolt. VEHICLE SPEED SENSOR
(7) Check the vehicle for the following: To Test - Code 24
(a) High fuel pressure.
(b) Leaking injector(s). (1) Check the fuel pump and meter fuses. If the
(c) Faulty ignition wiring. fuses are serviceable, proceed to operation (5). If a
fuse is blown, rectify the cause and renew the fuse.
Fuel and Engine Management 115
Erase the fault codes and retest for fault codes as (11) With the ignition switched On, backprobe
follows: the black and yellow wire terminal on the instrument
(2) Start and run the engine until normal oper- cluster wiring connector with a voltmeter to earth.
ating temperature is attained. The voltage should be over 10 volts.
(3) Drive the vehicle at a speed of at least 80 If the voltage is less than specified, locate the open
km/h and, with the throttle closed, allow the vehicle to circuit between the instrument cluster black and
decelerate until the engine speed is below 1 500 rpm. yellow wire terminal and the control unit wiring
connector terminal A10. Repair or renew the wiring
NOTE: After rectifying any fault it will be harness as necessary.
necessary to retest for fault codes. To test for (12) With a test lamp connected to 12 volts,
Code 24 the vehicle must be driven as backprobe the black wire terminals on the instrument
previously described. cluster wiring connectors. The test lamp should light.
(4) Switch the engine Off and connect a jumper If the test lamp does not light locate the open
lead between terminals A and B on the diagnostic link circuit between the black wire terminals and earth.
connector. Switch the ignition On and note the fault Repair or renew the wiring harness as necessary.
codes. If code 24 is displayed proceed as follows. If the test lamp does light, renew the signal
(5) Check the operation of the speedometer and divider circuit board which is located in the instru-
the instrument cluster warning lamps. If the speed- ment cluster.
ometer only is not functioning, proceed to operation (13) With the ignition switched On and the
(13). engine not running, disconnect the vehicle speed
If the speedometer and the instrument cluster sensor wiring connector from the harness connector.
warning lamps are not functioning, a fault in the (14) With a test lamp connected to earth, probe
instrument cluster wiring harness is indicated. Refer the yellow wire terminal on the harness wiring con-
the fault to an auto electrical workshop or a Nissan nector. The test lamp should light.
dealer. If the test lamp does not light, locate the open
If the speedometer is functioning, proceed as circuit between the yellow wire terminal and the Fuel
follows: Pump fuse. Repair or renew the wiring harness as
(6) Raise the front of the vehicle and support it necessary.
on chassis stands. (15) With a test lamp connected to 12 volts,
(7) Place the transaxle in Neutral and switch the probe the black wire terminal on the harness wiring
ignition On. connector. The test lamp should light.
(8) With the aid of assistants, slowly spin the If the test lamp does not light, locate the open
front wheels by hand while backprobing the control circuit between the black wire terminal and earth.
unit wiring connector terminal A10 with a digital
voltmeter to earth. Repair or renew the wiring harness as necessary.
The voltage should alternate from under 1 volt to (16) Using a voltmeter measure the voltage at the
over 10 volts. red wire terminal on the harness wiring connector.
If the voltmeter reading is not as specified, If the voltage is 5-9 volts proceed to operation
proceed to operation (9). (19).
If the voltmeter reading is as specified, the vehicle If the voltage is over 9 volts proceed to operation
speed sensor is operating satisfactorily, indicating an (18).
intermittent fault was the cause of the fault code.
Proceed as follows:
(a) Check for faulty wiring connections. Check
that all wiring connectors are clean and secure.
(b) Check that all earth connections are secure.
(9) Remove the instrument cluster as described
in the Electrical System section.
(10) With the ignition switched On, backprobe
the control unit wiring connector terminal A10 with a
voltmeter to earth. The voltage should be over 10
volts.
If the voltage is less than specified, check the
wiring harness for shorts to earth between the black
and yellow wire terminal on the instrument cluster
wiring connector and the control unit connector
terminal A10. Repair or renew the wiring harness as
necessary. If no fault can be found, renew the control
unit.
Installed view of the vehicle speed sensor.
116 Fuel and Engine Management
EMISSION CONTROL
DESCRIPTION
To reduce emissions and improve drivability
when the engine is cold, hot air is drawn into the air
cleaner from a heat shield which partially surrounds
the exhaust manifold.
When the ambient temperature is below 30°C, the
thermal vacuum valve, which is located inside the air
cleaner housing, allows vacuum to operate a servo
actuated flap in the air cleaner intake duct. When the
flap closes, hot air is drawn from the exhaust heat
shield, through the hot air inlet tube into the air
cleaner intake duct.
When the ambient temperature is above 30°C,
the flap in the air cleaner intake duct opens allowing View of the air cleaner raised showing the engine
cool air to enter the air cleaner. ventilation hose and the thermal vacuum valve supply
hose connection. 1.6 liter engine.
120 Emission Control
CLUTCH
SPECIFICATIONS
Type................................................... Single dry plate
Operation...................................................Mechanical
Pressure plate type....................................Diaphragm
Release bearing type.......................Prelubricated ball
Driven plate:
Outside diameter ....................................215 mm
Rivet depth limit ....................................0.3 mm
Runout limit .........................................0.5 mm
Maximum spline backlash ...................0.7 mm
Pressure plate:
Diaphragm spring height
(installed) ...................................... 30.5-32.5 mm
Spring finger variation limit.....................0.5 mm
Clutch pedal:
Height ..............................................175-185 mm
Free play ....................................... 12.5-17.5 mm Renew the clutch driven plate if the friction material is
Release lever free play............................ 2.5-3.5 mm worn down to, or is within 0.3 mm of the rivets.
Flywheel machining limit ...............................0.3 mm
NOTE: In most cases clutch slippage is first
TORQUE WRENCH SETTINGS evident by a marked increase in engine revs,
Pressure plate bolts.......................................... 29 Nm for no apparent reason, when pulling up a
Pedal pivot pin nut ......................................... 22 Nm steep hill. The clutch condition can be
Cable locknut .................................................... 4 Nm positively diagnosed as follows: With the
handbrake firmly applied, and the rear
Lower clutch housing to engine bolts..............21 Nm wheels chocked, select top gear and release
Centre and upper clutch housing the clutch with the engine running at ap-
to engine bolts..................................................49 Nm proximately 2 000 rpm. Clutch slippage is
evident if the engine does not stall. Make the
test as quickly as possible to prevent any
1. CLUTCH TROUBLE SHOOTING further clutch damage.
3. CLUTCH UNIT AND RELEASE (5) Disengage the clips retaining the release
MECHANISM bearing carrier to the release fork and slide the release
bearing assembly out of the clutch housing. Note the
Special Equipment Required: installed position of the retaining clips to aid assem-
To Install — Clutch aligning tool bly.
(6) Align the release fork retaining pins with the
TO REMOVE slots in the clutch housing and remove the pins using
a pin punch.
(1) Remove the transaxle from the vehicle as (7) Remove the release lever and shaft and
described in the Manual Transaxle section. withdraw the release fork and return spring from the
(2) Mark the pressure plate cover in relation to clutch housing.
the flywheel to ensure installation to the original
location.
(3) Progressively loosen and remove the pressure TO CHECK AND INSPECT
plate assembly retaining bolts working in a diagonal
sequence across the assembly. (1) Check the driven plate facings. Renew the
(4) Remove the pressure plate and driven plate driven plate if the facings are worn down to within
assemblies from the flywheel. Note the installed 0.3 mm of the rivet heads or are gummy and oil
direction of the driven plate to aid assembly. soaked.
(2) Check the driven plate hub cushion rubbers
for deterioration and damage. Renew the driven plate
if the hub is damaged.
(3) Mount the driven plate on the transaxle
input shaft and measure the spline backlash at the
outer edge of the driven plate. Renew the driven plate
if the spline backlash is beyond Specifications.
(4) Check the pressure plate assembly for wear
on the diaphragm spring fingers, cracked diaphragm
spring and a cracked or distorted cover. Check that
the pressure plate face is not badly scored.
(5) Check the flywheel face for heat cracks, burn
marks and scoring. Renew the flywheel if it is badly
scored.
NOTE: Slight glazing or burn marks on the
pressure plate or flywheel faces can be
corrected using emery paper. Minor scoring
Dismantled view of the flywheel, driven plate and on the flywheel face may be corrected by
clutch pressure plate. machining the flywheel.
(6) Rotate the release bearing by hand and check
for noise or roughness. Renew the bearing and carrier
as an assembly if faults are found.
(7) Check the release lever and shaft for wear
and damage. Renew as necessary.
(8) Check the release shaft bushes and seal for
wear or damage. Renew as necessary.
(9) Check the release fork for wear and the
return spring for fatigue. Renew as necessary.
TO INSTAL
(1) Sparingly apply lithium base molybdenum
disulphide grease to the transaxle input shaft splines,
release bearing carrier bore and rear contact surfaces,
release shaft bushes and release fork contact surfaces.
Slide the driven plate onto the transaxle input shaft
and remove the excess grease from the splines.
(2) Install the release shaft to the clutch housing,
return spring and release fork. Install the retaining pins
Dismantled view of the clutch release components.
124 Clutch
(3) Remove the nuts retaining the outer cable (3) If the pedal height is not as specified, adjust
flange to the vehicle bulkhead. the pedal stop bolt until the correct pedal height is
(4) Working inside the vehicle, disconnect the obtained.
inner cable from the top of the clutch pedal.
(5) Pull the clutch cable through the bulkhead TO ADJUST PEDAL AND RELEASE LEVER
into the engine compartment. FREE PLAY
(6) Release the clip retaining the centre of the
clutch cable and remove the cable from the vehicle. (1) Loosen the inner cable locknut at the release
(7) Check the inner cable for fraying, wear and lever clevis.
damage. Check the outer cable for kinks, wear and (2) Push the release lever until resistance is felt
damage. If necessary, renew the cable assembly. when the release bearing contacts the pressure plate
Installation is a reversal of the removal procedure fingers and hold the release lever in this position.
with attention to the following points: (3) Tighten the inner cable adjusting nut until
(1) Lubricate the inner cable ends with lithium the inner cable is taut.
base molybdenum disulphide grease prior to installa- (4) Loosen the adjusting nut 2.5-3.5 turns and
tion. tighten the inner cable locknut.
(2) Tighten the nuts retaining the outer cable (5) Measure the release lever free play. If the free
flange to a torque of 11 Nm. play is not as specified, loosen the locknut and turn
(3) Check and if necessary, adjust the clutch the adjusting nut until the correct free play is
pedal height and free play as described under the obtained.
heading Clutch Adjustments.
6. CLUTCH ADJUSTMENTS
TO ADJUST PEDAL HEIGHT
(1) Fold back the floor carpet and the sound
insulation from the drivers side floor panel.
(2) Measure the distance at right angles from the
floor panel to the centre of the pedal pad.
3. TRANSAXLE ASSEMBLY
TO DISMANTLE
(1) Remove the clutch release components from
Rear view of the transaxle removed from the vehicle.
130 Manual Transaxle and Drive Shafts
TO ASSEMBLE
(1) Lubricate all the components with the spec-
ified gear oil prior to assembly.
(2) Install new input shaft and striking rod
Check the mainshaft for pitting.
oil
(6) Inspect the striking rod, lever and interlock seals to the clutch housing in the direction noted on
for wear and damage paying particular attention to removal. Lubricate the oil seal lips with multipurpose
the detent grooves in the end of the striking rod. grease prior to installation.
Renew parts as necessary. (3) Assemble the components of the fifth gear
synchro assembly aligning the marks made on dis-
(7) Inspect the shift check and reverse check mantling. Ensure that the ends of the shift plate
balls and springs for wear, cracks and loss of tension springs are not aligned.
in the springs. Renew parts as necessary. (4) Install the split bearing to the rear of the
input shaft and install the fifth gear.
(5) Install the fifth gear synchro assembly and the
shift retainer to the rear of the input shaft. Ensure that
the slots in the synchro ring are aligned with the shift
Check the friction surfaces of the input shaft for pitting. Illustration showing the correct positioning of the shift
plates and springs.
Manual Transaxle and Drive Shafts 133
(32) Install and tighten the retaining bolts to fifth gear check assembly body. Apply locking com-
the specified torque. pound and tighten the reverse check plug securely.
(33) Repeat operation (29). The total turning (40) Using a bar clamped to the end of the
torque should be 5.9-13.7 Nm if new bearings have striking rod, check that a force of 4.9-7.4 Nm is
been installed or slightly less if the original bearings required to overcome the spring loading of the reverse
have been installed. and fifth gear check assembly. If necessary, renew the
If the turning torque is not as specified, adjust the springs to achieve this correct spring loading.
mainshaft turning torque as follows: NOTE: Ensure that the reverse check plug is
(a) Remove the transaxle case rear cover, O ring, coated with locking compound when finally
spacer and adjusting shim from the transaxle case. installed.
(b) Ensure that the mainshaft rear bearing outer
race is fully seated on the bearing cone. (41) Install the shift check ball, spring and plug to
(c) Using micrometer depth gauge, measure the the clutch housing. Ensure that the ball is centrally
distance from the transaxle case to the bearing outer located in the plug.
race and note the reading. (42) If removed, install the oil reservoir to the
clutch housing.
(d) Referring to the following table, select the
appropriate shim, according to the reading noted in (43) Install the input shaft assembly and the
reverse idler gear to the clutch housing taking care not
operation (c), required to correct the mainshaft turn- to damage the seal.
ing torque. (44) Apply locking compound to the bearing
retainer bolts and tighten the bolts to the specified
READING SHIM torque.
2.35-2.40 mm ............................................... 0.10 mm (45) Install the spacer to the reverse idler shaft.
2.40-2.45 mm ............................................... 0.15 mm (46) Install the differential assembly to the clutch
2.45-2.50 mm ...............................................0.20 mm housing.
2.50-2.55 mm ...............................................0.25 mm (47) Install the mainshaft to the clutch housing
2.55-2.60 mm ...............................................0.30 mm ensuring that the resin oil channel is located centrally
2.60-2.65 mm ............................................... 0.35 mm in the end of the mainshaft.
2.65-2.70 mm ............................................... 0.40 mm (48) Install the shift cap to the slot in the first/
2.70-2.75 mm ............................................... 0.45 mm
2.75-2.80 mm ............................................... 0.50 mm second shift fork and install the shift fork and control
2.80-2.85 mm ............................................... 0.55 mm bracket to the clutch housing. Use grease to hold the
2.85-2.90 mm............................................... 0.60 mm shift cap in the shift fork slot. Ensure that the reverse
2.90-2.95 mm............................................... 0.65 mm idler shift fork is correctly located over the gear.
2.95-3.00 mm............................................... 0.70 mm (49) Apply locking compound to the threads of
3.00-3.05 mm ............................................... 0.75 mm the control bracket retaining bolts and tighten the
3.05-3.10 mm ............................................... 0.80 mm bolts to the specified torque.
3.10-3.15 mm............................................... 0.85 mm (50) Install the shift cap in the slot in the third/
3.15-3.20 mm............................................... 0.90 mm fourth shift fork and install the fork to the transaxle
3.20-3.25 mm............................................... 0.95 mm assembly. Use grease to hold the shift cap in the shift
3.25-3.30 mm ...............................................1.00 mm. fork slot.
(51) Install the fifth gear shift fork to the transaxle
(e) Install the spacer, shim, O ring and rear ensuring that the shift fork slot engages the control
cover to the transaxle case. Tighten the retaining finger.
bolts securely. (52) Install the fork shaft and spring to the clutch
(34) Measure the total turning torque as previ- housing sliding the shaft through the shift forks. Use
ously described. grease to hold the spring in the end of the shaft.
(35) Install the striking interlock and striking lever (53) Apply a continuous bead of sealant to the
to the clutch housing. mating face of the clutch housing so that the bead is
(36) Install the striking rod to the clutch housing located inside the row of bolt holes.
sliding the rod through the lever and interlock. Take
care that the end of the rod does not damage the seal.
(37) Install a new retaining pin to the striking rod NOTE: Sealant is available from Nissan
using a pin punch. spare parts using the part number KP
(38) Install the reverse and fifth gear check 610-00250.
assembly to the clutch housing. Tighten the retaining (54) Install the transaxle case to the clutch hous-
screws securely. ing. Install and tighten the retaining bolts to the
(39) Install the balls, spring and reverse check specified torque.
plug to the clutch housing ensuring that the smaller
diameter ball enters the hole in the body of the (55) Select each gear in turn and check that the
reverse and transaxle turns freely in each gear. Ensure that it is not
Manual Transaxle and Drive Shafts 135
possible to move the striking rod from fifth gear to removal of the transaxle from the vehicle. Operations
reverse without first moving sideways in the neutral 1-9 of the dismantling procedure under the same
gate. heading describe the removal of the differential and
final drive assembly from the transaxle.
(1) If necessary, cut and remove the speedome-
ter drive gear from the differential case.
4. DIFFERENTIAL AND FINAL DRIVE (2) Using a suitable puller, remove the differen-
ASSEMBLY tial carrier bearing cone and roller assemblies from the
differential case and remove the speedometer drive
Special Equipment Required: gear stopper.
To Measure Differential Turning Torque — (3) Remove the ring gear retaining bolts and
Suitable slotted adaptor and torque gauge separate the ring gear from the differential case using
a soft faced hammer.
TO CHECK VISCOUS COUPLING (4) Using a pin punch, remove the retaining pin
From July 1989, Manual transaxle Pulsar Q and from the differential pinion shaft.
Vector SSS models are equipped with a limited slip (5) Remove the pinion shaft from the differen-
differential incorporating a viscous coupling. tial case.
(1) Raise the front of the vehicle and support it (6) Remove the pinion gears and thrust washers
on chassis stands. from the differential case.
(2) Rotate one front wheel and check the rota- (7) Remove the side gears and spacers from the
tional direction of the opposite wheel. differential case.
(3) If both front wheels rotate in the same NOTE: If applicable, the viscous coupling is
direction, the viscous coupling is functioning nor- integral with the left hand side gear.
mally.
(4) If the front wheels rotate in opposite direc- (8) Wash all the differential components with
tions, the viscous coupling is unserviceable and must cleaning solvent.
be renewed as an assembly. (9) Check the gears, spacers, thrust washers,
pinion shaft and differential case for wear, pitting and
TO DISMANTLE AND ASSEMBLE damage. Renew parts as necessary.
It is necessary to remove and dismantle the (10) Install the side gears and spacers to
transaxle assembly to gain access to the differential the
and final drive assembly. differential case.
Refer to the Transaxle Assembly heading for the (11) Install the pinion gears and thrust washers
to
the differential case.
(12) Install the pinion shaft to the differential case
aligning the retaining pin hole.
(13) Install the retaining pin to the pinion shaft
until the end of the pin is level with the differential
case.
(14) With a dial gauge contacting the end of the
side gear, lift the side gear evenly and measure the
clearance between the side gear and the differential
case. The clearance should be 0.1-0.2 mm.
NOTE: Do not tilt the side gear or the dial
gauge reading will be incorrect.
(15) If necessary, adjust the side gear clearance
using selective fit spacers.
NOTE: Spacers are available from 0.15 mm
to 1.00 mm in increments of 0.05 mm.
(16) Measure and if necessary, adjust the other
side gear clearance.
(17) On models equipped with a viscous cou-
pling, adjust the side gear clearance as follows:
(a) Temporarily secure the differential case with
View of the differential assembly removed from the two bolts.
transaxle. (b) Position the differential case so that the right
hand side gear is uppermost.
(c) Insert a 0.03 mm feeler gauge between the
136 Manual Transaxle and Drive Shafts
right hand side gear and the adjacent spacer in an area 0.74-0.78 mm................................................... 1.08 mm
where there is no oil groove in the differential case. 0.78-0.82 mm................................................... 1.12 mm
(d) Insert another 0.03 mm feeler gauge diago- 0.82-0.86 mm................................................... 1.16 mm
nally opposite the first feeler gauge to avoid tilting the 0.86-0.90 mm................................................... 1.20 mm
side gear. 0.90-0.94 mm................................................... 1.24 mm
(e) Insert a splined adaptor into the right hand 0.94-0.98 mm................................................... 1.28 mm
side gear and attempt to rotate the gear by hand. 0.98-1.02 mm................................................... 1.32 mm
(f) If the gear cannot be rotated, change the 1.02-1.06mm................................................... 1.36 mm
thickness of the left hand side gear spacer, repeating 1.06-1.10mm................................................... 1.40 mm
the test until the gear can be rotated. 1.10-1.14mm................................................... 1.44 mm
NOTE: Spacers are available in thicknesses 1.14-1.18mm................................................... 1.48 mm
from 0.8 mm to 1.5 mm in increments of 1.18-1.22mm................................................... 1.52 mm
0.1 mm. 1.22-1.26mm................................................... 1.56 mm
1.26-1.30mm................................................... 1.60 mm
(g) Remove the 0.03 mm feeler gauges and insert 1.30-1.34mm................................................... 1.64 mm
0.09 mm feeler gauges to the same position. The gear 1.34-1.38mm................................................... 1.68 mm
should lock. 1.38-1.42mm................................................... 1.72 mm
(h) The spacer selection is correct when the right 1.42-1.46mm................................................... 1.76 mm
hand side gear can be rotated with 0.03 mm feeler
gauges inserted but locks when 0.09 mm feeler gauges The thickest shim available is 0.88 mm. Multiple
are inserted. shims are required above this thickness.
(18) Install the ring gear to the differential case (28) Install the shim behind the carrier
with the chamfered edge of the ring gear inwards. bearing
(19) Install and tighten the retaining bolts in outer race in the transaxle case and assemble the unit
a once more.
diagonal sequence to the specified torque. (29) Using a suitable slotted adaptor engage the
(20) Install a new speedometer drive gear to pinion shaft and using a torque gauge, measure the
the differential turning torque.
differential case. Install the stopper adjacent to the The turning torque when new carrier bearings
drive gear. have been installed should be 3.9-7.8 Nm or slightly
(21) Install the differentia] carrier bearing lower if the original carrier bearings have been
cones replaced.
and roller assemblies to the differential case. (30) Assemble the transaxle and measure the total
(22) Remove the adjusting shim from behind the turning torque of the differential assembly and the
carrier bearing outer race in the transaxle case and mainshaft. The total turning torque should be 5.9 to
replace the outer race in the transaxle case. 13.7 Nm with new bearings or slightly lower if the
(23) Install the differential assembly to the clutch original bearings have been replaced.
housing.
(24) Install the transaxle case to the clutch housing
and tighten the retaining bolts to the specified torque. 5. GEAR LEVER ASSEMBLY
(25) Mount a dial gauge to the clutch housing so
that the contact point is resting on the differential TO DISMANTLE AND ASSEMBLE
case. (1) Remove the gear lever knob and remove the
(26) Insert a bar through the opposite side gear centre console as described in the Body section. If not
and, contacting the pinion shaft, raise and lower the previously removed, remove the rubber boot sur-
differential case and measure the end float in the rounding the gear lever.
carrier bearings. (2) Raise the front of the vehicle and support it
(27) Using the following table, select a shim to on chassis stands. Remove the catalytic converter and
correspond to the relevant end float. heat shield as described in the Engine section.
END FLOAT SHIM THICKNESS (3) Remove the bolt and disconnect the control
0.30-0.34 mm....................................................0.64 mm rod from the bottom of the gear lever, noting the
0.34-0.38 mm................................................... 0.68 mm position of the return spring and bracket.
0.38-0.42 mm................................................... 0.72 mm (4) Remove the nuts retaining the gear lever
0.42-0.46 mm................................................... 0.76 mm socket to the support rod.
0.46-0.50 mm................................................... 0.80 mm (5) Working inside the vehicle, lift the gear lever
out of the floor bracket.
0.50-0.54 mm................................................... 0.84 mm (6) Separate the lower rubber boot, socket,
0.54-0.58 mm................................................... 0.88 mm spring seat, spring, upper ball seat and lower ball seat
0.58-0.62 mm................................................... 0.92 mm from the gear lever, noting the location of each
0.62-0.66 mm................................................... 0.96 mm component to aid assembly.
0.66-0.70 mm................................................... 1.00 mm
0.70-0.74 mm................................................... 1.04 mm
Manual Transaxle and Drive Shafts 137
6. DRIVE SHAFTS
TO REMOVE AND INSTAL
(1) Remove the dust cap from the centre of the
front hub. Remove the split pin and nut retainer from
the outer end of the drive shaft.
(2) With an assistant applying the brakes, loosen
the nut on the outer end of the drive shaft.
(3) Raise the front of the vehicle and support it
on chassis stands. If necessary, refer to the Wheels and
Tires section for the correct jacking points.
Brakes section if necessary. Suspend the caliper with (11) Inspect the ball cage and the balls for wear
wire or cord attached to the coil spring. and damage.
(9) Hold the steering knuckle and hub assembly (12) Rotate the drive shaft with the outer C.V.
and tap the drive shaft out of the hub using a soft joint at a sharp angle and inspect the internal
faced hammer. components of the outer C.V. joint for wear and
(10) Drain the oil from the transaxle into a damage. Renew if necessary by tapping the C.V. joint
container. from the drive shaft.
(11) Prise the drive shaft out of the transaxle and
remove the drive shaft from the vehicle. NOTE: Do not reuse the retaining snap ring
Installation is a reversal of the removal procedure if the C. V. joint is removed from the drive
with attention to the following points: shaft.
(1) Ensure that the drive shaft is firmly attached (13) Check the C.V. joint boots for damage and
to the differential side gear by attempting to pull the deterioration.
shaft out of the gear. (14) Renew all worn or damaged components as
(2) Tighten all nuts securely and install new split necessary.
pins. Assembly is a reversal of the dismantling proce-
(3) Fill the transaxle with the specified grade and dure with attention to the following points:
quantity of oil. (1) Thoroughly pack the outer C.V. joint with
molybdenum disulphide grease.
TO DISMANTLE AND ASSEMBLE (2) Install the outer C.V. joint boot and retain in
(1) Remove the drive shaft from the vehicle as position using new retaining clips. Ensure that the
previously described. boot and the clips are correctly seated.
(2) Remove and discard both the inner C.V. (3) Install the inner C.V. joint boot, small
joint boot retaining clips from the inner C.V. joint. end
(3) Roll back the large end of the inner C.V.- first, onto the drive shaft and pull it well down the
joint boot using a thin blade screwdriver, prise out the shaft.
C.V. joint retaining ring. (4) Install the outer snap ring for the inner C.V.
(4) Withdraw the C.V. joint housing from the joint into its locating groove in the drive shaft.
drive shaft and ball assembly. (5) Position the inner ball race inside the ball
(5) Remove the inner snap ring retaining the ball cage with the chamfered end of the ball race towards
assembly to the drive shaft and withdraw the ball the small end of the cage.
assembly. (6) Press the balls firmly into the ball cage,
(6) Remove the remaining inner C.V. joint re- ensure that the balls are fully seated.
taining snap ring and the C.V. joint boot from the (7) Install the ball assembly onto the drive
shaft
drive shaft. with the small end of the cage towards the outer C.V.
(7) Noting their installed positions remove the joint and install the inner snap ring retaining the
cage and ball assembly off the inner race and press the ball
balls out of the cage. assembly onto the drive shaft.
(8) Remove and discard the clips retaining the (8) Pack the C.V. joint with the prescribed
outer C.V. joint boot to the drive shaft and remove amount of molybdenum disulphide grease. Refer to
the C.V. joint boot. Specifications.
NOTE: The outer C.V. joint cannot be (9) Install the C.V. joint retaining ring into the
dismantled. C.V. joint housing. Ensure that the retaining ring is
correctly seated.
(9) Wash all parts in a suitable solvent and blow
dry with compressed air.
(10) Inspect the ball contact faces of the inner ball
race and C.V. joint housing for pitting and wear.
Install the ball assembly onto the drive shaft, with the
Dismantled view of the inner C.V. joint. small end of the cage towards the outer C.V. joint.
Manual Transaxle and Drive Shafts 139
SNAP RING
Install the C.V. joint retaining ring into the C.V. joint
Assembled view of the inner C.V. joint. housing. Ensure that the retaining ring is correctly
seated.
(10) Slide the large end of the inner C.V. joint NOTE: Ensure that the retaining dips are
boot over the inner C.V. joint housing and locate the securely installed preventing the entry of
boot in the groove in the housing. damaging dust or water and that the lock
(11) Pull the C.V. joint until the boot is the tabs on the retaining clips are correctly bent
normal length. Deformation of the boot could occur if over.
this operation is neglected. (13) Install the remaining snap ring onto the inner
(12) With no vacuum or pressure present in the C.V. joint housing shaft and install the drive shaft to
C.V. joint boot, install the two C.V. joint boot the vehicle as previously described.
retaining clips.
140
AUTOMATIC TRANSAXLE
NO DRIVE IN D RANGE
{1) Low fluid level in transaxle: Check the fluid
level in the transaxle and top up if required.
3. TRANSAXLE FLUID
Only use the recommended transaxle fluid speci-
fied by the manufacturer when topping up or changing
the fluid in the system. Checking the fluid level on the automatic transaxle
dipstick.
142 Automatic Transaxle
4. BRAKE BAND (4) Slowly depress the throttle pedal to the full
throttle position.
Band adjustment is not a normal maintenance The outer kickdown cable will automatically ad-
procedure. just and emit a clicking noise.
The adjustment entails removal of the valve body
and for this reason the vehicle should be taken to an 6. TRANSAXLE SELECTOR LINKAGE
authorized dealer.
TO ADJUST CONTROL CABLE
5. KICKDOWN CABLE
(1) Place the selector lever in the Park position.
TO ADJUST (2) Loosen the control cable locknuts and ensure
that the transaxle selector lever is in the Park position.
(1) On models with a 1.6 liter engine, remove
the air cleaner assembly.
(2) With the aid of an assistant, ensure that the
throttle valve is fully open when the throttle pedal is
fully depressed.
(3) Push the clip on the outer kickdown cable
and pull the cable away from the throttle linkage.
View of the kickdown cable adjustment point. The 7. NEUTRAL SAFETY SWITCH
arrow indicates the direction in which the outer kick-
down cable must be pulled to initiate the automatic
adjustment. 1.8 liter engine. The neutral safety switch, incorporating the re-
verse lamp switch is located on the transaxle case
Automatic Transaxle 143
facing towards the radiator support panel at the front (3) Align the holes in the neutral safety switch
of the vehicle. body and the neutral safety switch arm.
The neutral safety switch allows electrical current (4) Install a 2.5 mm diameter split pin or drill bit
to pass to the starter circuit only when the selector into the holes to align the arm with the neutral safety
lever is in the Park or Neutral position. The switch is switch body.
adjustable but non-repairable. (5) Secure the retaining bolts and test the switch
as previously described.
TO TEST If the test indicates a fault, renew the neutral
(1) Disconnect the neutral safety switch wiring safety switch.
connector.
(2) Connect an ohmmeter between terminals 1 TO REMOVE AND INSTAL
and 2 at the neutral safety switch wiring connector.
Continuity should exist when the selector lever is in (1) Raise the front of the vehicle and support it
the P or N positions. on chassis stands.
(3) Perform the same check with terminals 3 and (2) Remove the selector cable split pin and wave
4 with the selector lever in the R position. Continuity washer from the transaxle selector lever.
should exist. (3) Disconnect the electrical connector and re-
NOTE: If the readings are other than that move the neutral safety switch retaining bolts.
(4) Maneuver the neutral safety switch clear of
specified, the neutral safety switch will have the transaxle selector lever and withdraw the switch
to be adjusted or renewed. from the vehicle.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Clean the area around the neutral safety
switch mounting.
(2) Apply a small amount of chassis grease to the
jaws of the neutral safety switch arm.
(3) Check the adjustment of the selector cable as
previously described.
(4) Adjust the neutral safety switch as previ-
ously described.
(5) Check the operation of the neutral safety
switch and ensure that the engine will not start in any
position other than P and N. Check that the reversing
Neutral safety switch connector terminal identification. lamps operate only when R is selected.
TO ADJUST
(1) Select Neutral and firmly apply the hand- 8. TRANSAXLE ASSEMBLY
brake.
(2) Loosen the neutral safety switch retaining Special Equipment Required:
bolts. To Remove and Install — Suitable trolley jack to
which the transaxle can be secured
CONVERTER HOUSING
Installation is a reversal of the removal procedure with the marks made on removal.
with attention to the following points: (5) Install the torque converter retaining bolts.
(1) Check the torque converter drive plate for (6) Turn the engine over by hand several times
any damage, wear and runout. The maximum runout to ensure that the torque converter is not binding.
permissible is 0.50 mm. (7) Use only the specified type and quantity of
(2) Ensure that the torque converter is fully transaxle fluid.
engaged in the transaxle before attempting to install (8) Connect and adjust the neutral safety switch
the transaxle to the engine. and kickdown cable as previously described.
(3) Install the transaxle assembly to the vehicle (9) Road test the vehicle and check the opera-
and install the converter housing retaining bolts. tion of the kickdown cable and selector cable.
(4) Align the torque converter and drive plate (10) After road testing inspect the transaxle for
any fluid leaks and rectify as required.
145
STEERING
PART 1. STEERING TROUBLE SHOOTING
FAULTS, CAUSES AND REMEDIES (2) Low fluid level in the power steering reser-
voir: Check for leakage, repair and/or renew the faulty
EXCESSIVE PLAY OR LOOSENESS IN components. Top up the fluid level.
STEERING GEAR (3) Suspension worn or out of alignment: Check
(1) Tie rod end ball joint loose or worn: Tighten the front suspension for wear, renew the worn com-
or renew the worn tie rod end ball joint. ponents and realign.
(2) Steering gear assembly loose on cross- (4) Misalignment between the steering gear and
member: Inspect for damage and tighten the steering column mountings: Check and align the steering gear
gear mounting bolts. and column mountings.
(3) Steering gear worn: Overhaul the steering (5) Binding in the steering shaft universal coup-
gear. ling joints: Check the joints and renew if necessary.
(6) Ingress of dirt into the steering gear due to a
defective boot: Clean, check and lubricate the internal
components of the steering gear and renew the
defective boot.
(7) Insufficient power steering pump pressure:
Check the pump drive belt tension and reservoir fluid
level. If necessary renew the pump assembly.
NOTE: Ensure that both front tires have
ample depth of tread and are inflated to the
correct pressure. Check the front suspension
components for wear before having the steer-
ing geometry checked. See the Front Sus-
pension section for the component checking
procedures.
Check the tie rod ends for wear and the rubber boots
for deterioration.
View of the steering column assembly removed from Dismantled view of the steering lock and ignition
the vehicle. Steering column length is shown as dimen- switch assembly.
sion A. A - 534.7-537.3 mm.
Steering — Part 2 149
View of the steering gear and associated components removed from the vehicle.
mark the universal coupling joint in relation to the (3) Thoroughly clean the exterior of the steering
steering gear pinion as an aid to installation. gear in a suitable cleaning solvent.
(2) Remove the bolt retaining the universal (4) Secure the steering gear in a soft jawed vice
coupling joint to the steering gear pinion. and centralize the rack in the steering gear.
(3) Raise the front of the vehicle, support it on (5) Loosen both the tie rod end locknuts and
chassis stands at the jacking points and remove the unscrew the tie rod ends from the tie rods, noting the
front wheels. Refer to the Wheel and Tires section. number of turns required to do so. Remove the
(4) Remove the split pins and castellated nuts locknuts from the tie rods.
from the tie rod end studs and disconnect the tie rod (6) Remove the tie rod rubber boot retaining
ends from the steering arms. clamps, detach the boots from the steering gear
housing and slide them from the tie rods. Take care to
NOTE: Disconnect each tie rod end by position a container to catch the oil contained in the
placing a suitable dolly or hammer against steering gear assembly.
one side of the steering arm eye and striking (7) Where the tie rod ball housing is retained by
the opposite side with a hammer. staking, drill the staking away from the rack and tie
(5) Remove the bolts from the steering gear rod using a 4.0 mm drill. Do not drill into the rack
mounting brackets. more than is necessary to drill out the staking.
(6) Separate the steering gear pinion from the Where the tie rod ball housing is retained by a
universal coupling joint and maneuver the steering lock pin, drill out the lock pin from the ball housing
gear from the vehicle. and tie rod using a 4.0 mm drill. Do not exceed a
Installation is a reversal of the removal procedure drilling depth of 10.0 mm.
with attention to the following points:
(1) Ensure that the steering gear mounting
bracket rubbers are in good condition. Renew if
necessary.
(2) Renew the split pins on the tie rod castel-
lated nuts.
(3) Check and if necessary adjust the front wheel
toe in. Refer to the Front Suspension section for the
correct procedure.
TO OVERHAUL
To overhaul the steering gear a range of special
tools is required. If the steering gear has a fault
which requires the removal of the rack or pinion it
is recommended that the necessary repairs be car-
ried out by an authorized dealer.
(8) Slide the rack out of the housing slightly so toe in as described in the Front Suspension section
that an adjustable spanner can be used to hold the under the appropriate heading.
rack.
(9) Using a Stillsons wrench, unscrew the ball TO RENEW TIE ROD END
housings in turn using care not to allow the rack to (1) Raise the front of the vehicle and support it
rotate. Keep all the tie rod parts in order. on chassis stands.
(10) Inspect the rack boots for cracks and deteri- (2) Remove the relevant front wheel.
oration and renew as necessary. (3) Loosen the tie rod end locknut and remove
(11) Inspect the tie rod ends for wear and damage the tie rod end castellated nut. Disconnect the tie rod
and renew as necessary. from the steering arm by placing a suitable dolly or
hammer against one side of the steering arm eye and
striking the opposite side with a hammer.
(4) Unscrew the tie rod end from the tie rod,
noting the number of turns necessary to remove it.
(5) Screw the new tie rod end onto the tie rod
the same number of turns noted during removal.
(6) Connect the tie rod to the steering arm and
install the castellated nut. Tighten the nut to the
specified torque and secure it with a new split pin.
(7) Install the front wheel and lower the vehicle
Dismantled view of the tie rod ball housing and the tie to the ground.
rod end assemblies removed from the steering gear. (8) Check and if necessary, adjust the front
wheel toe in as described in the Front Suspension
Assembly is a reversal of the dismantling proce- section. Ensure that the rubber boots are not distorted
dure with attention to the following points: or twisted on the tie rod when the adjustment is
(1) Using large Stillsons and a large adjustable completed.
spanner, install the tie rod and ball housing
assemblies TO RENEW RUBBER BOOT
to the rack. Tighten the ball housings to the specified (1) Raise the front of the vehicle and support it
torque. on chassis stands.
NOTE: To avoid damage to the rack or (2) Remove the relevant tie rod end as previ-
pinion the adjustable spanner must be ously described.
(3) Release the clamps securing the boot to the
firmly tightened over the rack teeth and the tie rod and steering gear housing.
rack must not be allowed to rotate when (4) Unscrew and remove the locknut from the
installing the ball housings. tie rod.
(2) Measure a point 9 mm in from the rear face (5) Remove the rubber boot together with the
of the ball housing of the rack and at 90 deg to the outer retaining clamp from the tie rod.
rack teeth. Centre punch this point. (6) Sparingly lubricate the tie rod boot groove
(3) At this point drill a 4 mm hole, 10 mm deep with EPL 1 grease, install the new boot to the tie
through the rack and into the ball housing thread. rod
(4) Place a locking pin above the hole and drive and push it onto the steering gear rack housing. Install
it into position. and secure the inner and outer retaining clamps.
(5) Lubricate the rack, rack teeth and tie rod (7) Install the tie rod end locknut and screw
boot groove with suitable EPL 1 grease. the
(6) Install the rack boots and secure with the tie rod end onto the tie rod the same number of turns
clamps. Renew the clamps if necessary. noted during removal.
(7) Install the tie rod end locknuts and then the (8) Connect the tie rod to the steering arm and
tie rod ends, ensuring that they are screwed on the
same number of turns as was necessary to remove install the castellated nut. Tighten the nut to the
them. specified torque and secure it with a new split pin.
(8) Tighten the locknuts to the specified torque. (9) Install the wheel and lower the vehicle to the
(9) Install the mounting rubbers and brackets ground.
to (10) Check and if necessary, adjust the front
the steering gear as noted on removal. wheel toe in as described in the Front Suspension
(10) Install the steering gear assembly to section. Ensure that the rubber boots are not distorted
the or twisted when the adjustment is completed.
vehicle as previously described.
(11) Check and if necessary adjust the front wheel
152
3. STEERING WHEEL
The procedure for removing and installing the
steering wheel is fully covered in the Manual Steering
section under the above heading.
Checking the power steering fluid level using the
dipstick incorporated in the cap. 4. STEERING COLUMN
TO CHECK FOR FLUID LEAKS The procedure for removing, dismantling and
assembling the steering column is fully covered in the
Using a suitable solvent, clean around all power
steering assemblies and hose fittings where fluid Manual Steering section under the above heading.
leakage might occur and start the engine. Turn the
steering wheel from one steering lock to the other 5. POWER STEERING PUMP
several times and stop the engine. Check for leakage.
Where leakage is found at hose fittings, tighten and TO REMOVE AND INSTAL
recheck. (1) Disconnect the negative battery terminal.
If the leak remains, renew the hoses or fittings as
required.
Where leakage is found in the steering gear
assembly or pump assembly, specialist attention is
necessary.
TO CHECK STEERING WHEEL FREE PLAY
With the engine running and the steering wheel in
the straight ahead position, measure the free move-
ment of the steering wheel before the front wheels
move. This is specified as steering wheel free play and
if it exceeds Specifications, check for free play in the
steering linkages and the universal coupling joints. If
these components are satisfactory, it will be necessary
to remove the steering gear from the vehicle for
renewal or overhaul.
PUMP BELT TENSION
The procedure for adjusting the power steering
pump bell tension is described in the Engine Tune-up View of the power steering pump removed from the
section vehicle.
154 Steering —
(4) Support the rack carefully and lever back the boots with the clamps and clips ensuring that the clips
tabs of the ball housing lock washers. To prevent are facing downwards.
damage to the steering gear, avoid any impact to the (5) Install the tie rod end locknuts and tie rod
steering rack. ends to the tie rod. Install the tie rod ends the same
(5) Holding the rack with an adjustable spanner, number of turns noted on removal. Tighten the lock-
unscrew the ball housings from the rack using a nuts to the specified torque.
Stillsons wrench. Remove and discard the lock wash- Install the power steering gear assembly to the
ers. vehicle as described under the previous heading and
Installation is a reversal of the removal procedure bleed the system as described under the heading In
with attention to the following points: Car Adjustments, Checks and Minor Repairs.
(1) Install the new lock washer to the
rack,
ensuring that the lockwasher tangs are located in the TO RENEW RUBBER BOOTS
rack end. The procedure to renew the rubber boots is fully
(2) Install the ball housing assemblies to the rack. covered in the Manual Steering section under the
Tighten the ball housings to the specified torque and Steering Gear Assembly heading.
secure by bending the lock washer.
(3) Before installing the rubber boots ensure that
the vent holes, located towards each end of the rack TO RENEW TIE ROD ENDS
near the ball housings, are clear. If necessary clear the
hole with a suitable probe. The procedure to renew the tie rod ends is fully
(4) Apply sealant to the large end of the rubber covered in the Manual Steering section under the
boot and grease to the small end. and install the boots, Steering Gear Assembly heading.
being careful not to damage or twist them. Secure the
156
FRONT SUSPENSION
SPECIFICATIONS
Type.................. Independent MacPherson strut with
coil springs and control arms
Shock absorber ..................Hydraulic, non-repairable
Hub bearing end float (maximum) ............. 0.05 mm
Ball joint axial play (maximum)....................0.7 mm
Ball joint turning torque (used)...............0.5-4.9 Nm
Wheel alignment:
Toe in ..................................................... 0-2 mm
Camber ........................................-0 ° 1 0 ' ± 4 5 '
Caster..............................................1° 10' ± 45'
King pin inclination..................... 13° 55' ± 45'
TORQUE WRENCH SETTINGS
Hub bearing nut..................................... 196-235 Nm Check the ball joints for wear and deterioration.
Suspension unit to steering knuckle nut ...... 118 Nm
Suspension unit to body nuts ......................... 29 Nm (7) Worn stabilizer bar link ball joints: Renew
Piston rod nut.................................................. 72 Nm the stabilizer bar links.
Brake caliper to steering knuckle bolts ...........52 Nm (8) Drive shafts worn or insufficiently lubri-
Ball joint to steering knuckle bolt...................86 Nm cated: Check the lubricant and the dust boots and
Control arm bracket bolts ...............................98 Nm renew as necessary.
Control arm pivot bolt ................................ 118 Nm (9) Drive shaft splines in the hub or the
Stabiliser bar link nuts.....................................44 Nm differential worn or damaged: Check and renew as
Stabiliser bar bracket bolts..............................21 Nm necessary.
NOTE: To check the front suspension com-
1. FRONT SUSPENSION TROUBLE ponents for wear, raise the front of the
SHOOTING vehicle, support it on chassis stands and
allow both front wheel to hang free. With an
FRONT END NOISE assistant pushing and pulling the front
wheels in and out at the top and then at the
(1) Loose upper suspension mounting or piston bottom, check for excessive looseness at the
rod: Tighten the mounting or piston rod nuts. front hub bearings and lower control arm
(2) Loose or worn suspension unit lower ball inner pivot bushes. Noise or vibration in the
joint: Tighten or renew the lower ball joint. front end can also be caused by excessive
(3) Noise in the suspension unit: Renew the tire or wheel unbalance. Drive shaft joint
faulty suspension unit, preferably in pairs. noise is usually more pronounced when
(4) Worn or loose steering gear: Overhaul the moving slowly with the steering on full lock.
steering gear assembly.
(5) Worn front hub bearings: Renew the hub POOR OR ERRATIC ROAD HOLDING
bearings: ABILITY
(6) Loose or defective stabilizer bar, control arm (1) Low or uneven tire pressures: Inflate the
or mountings: Check, tighten or renew the mounting tires to the recommended pressures.
rubbers. (2) Defective suspension unit: Renew the faulty
unit, preferably in pairs.
Front Suspension 157
2. DESCRIPTION
Check the stabilizer bar links for wear and damage. The front suspension is an independent type
(3) Incorrect front end alignment: Check and comprising two Macpherson strut suspension units
adjust the alignment as necessary. mounted vertically on each side of the vehicle. The
(4) Defective stabilizer bar mounting rubbers or lower end of the suspension unit is bolted to the
worn link ball joints: Renew component as necessary. steering knuckle, which in turn houses the front hub
(5) Weak or broken front coil spring: Renew bearings. The steering knuckle pivots on the control
both springs as a matching pair. arm by means of a ball joint.
(6) Broken or weak rear coil spring: Renew both The control arm pivots at its inner ends on rubber
springs as matching pair. bushes.
(7) Drive shaft bent or distorted: Check and A stabilizer bar is attached to both ends of the
renew as necessary. control arms using ball joint links. The stabilizer bar
(8) Tie rod end worn or damaged: Check and is attached to the front underbody by brackets and
renew as necessary. mounting rubbers.
(9) Control arm ball joint worn or damaged: Each front suspension unit assembly comprises a
Check and renew as necessary. tubular shock absorber type suspension unit, sur-
(10) Control arm mounting bolts loose: Tighten rounded at the upper end by a coil spring. On top of
the control arm bolts. the coil spring is the upper mounting which attaches
(11) Wheel hub bearing worn: Check and renew to the underside of the inner mudguard panel. The
piston rod of the suspension unit is attached to the
as necessary. centre of the upper mounting by a rubber mounted
bearing.
When a suspension unit is found to be defective it
is recommended that both suspension units be re-
newed as a pair.
Camber is adjusted by means of a cam on the
upper steering knuckle to suspension unit mounting
bolt.
The kingpin inclination and caster are set in
production and cannot be adjusted. Any variation in
these angles will be caused by worn or damaged
components.
3. STEERING KNUCKLE
Installed view of the front suspension. When using a floor jack locate the head of the jack on the crossmember.
(2) Remove the cap, split pin, castellated re- steering knuckle using a suitable puller or alternatively
tainer and with the aid of an assistant applying the place a suitable dolly or hammer against one side of
brakes, loosen and remove the hub nut. the steering knuckle eye and strike the opposite side
(3) Remove the split pin and the castellated nut with a hammer.
retaining the tie rod end to the steering knuckle. (12) Withdraw the steering knuckle from the
(4) Disconnect the tie rod end from the steering vehicle taking care not to drop the drive shaft or
knuckle using a suitable puller. Alternatively place a damage its boot.
suitable dolly or hammer against one side of the (13) Clean and check the steering knuckle for
steering knuckle eye and strike the opposite side with wear, cracks and damage.
a hammer. (14) If necessary, dismantle the hub and check
(5) Remove the brake caliper anchor plate bolts, the bearing assembly using the dismantling procedure
withdraw the caliper from the disc and support it with described later in this section.
a piece of wire inside the inner mudguard. Ensure that Installation is a reversal of the removal procedure
the brake hose is not twisted. with attention to the following points:
(6) Withdraw the brake disc from the hub. (1) Install the steering knuckle and hub assembly
(7) Loosely install the hub nut and tap on the nut over the drive shaft and loosely install the ball joint
with a soft faced hammer to separate the drive shaft stud nut and the suspension unit to knuckle bolts and
from the hub. nuts.
(8) Place a mark on the suspension unit to (2) Ensure that the suspension unit to steering
steering knuckle cam head bolt to ensure correct wheel knuckle cam head bolt marks are aligned and tighten
alignment on assembly. the retaining nuts to the specified torque.
(9) Remove the steering knuckle to suspension
unit nuts and bolts. NOTE: If the cam head bolt is not installed
(10) Remove the split pin and the castellated nut in its original position, a wheel alignment
retaining the lower ball joint stud to the steering should be performed.
knuckle. (3) Tighten the ball joint to steering knuckle stud
(11) Disconnect the ball joint stud from the bolt to the specified torque.
Front Suspension 159
(4) Install the tie rod end to the steering knuckle using an angle grinder and split the race using a cold
and tighten the castellated nut securely. Install a chisel.
new (7) Thoroughly clean and dry the steering
split pin. knuckle and hub in a suitable solvent.
(5) Install the brake disc to the hub. (8) Inspect all the components for wear, damage
(6) Install the brake caliper to the steering and cracks and renew if necessary.
knuckle and tighten the retaining bolts to the specified TO ASSEMBLE
torque.
(7) Install the hub nut and washer to the Assembly is a reversal of the dismantling proce-
drive dure with attention to the following points:
shaft and with the aid of an assistant applying the (1) Apply grease to the oil seal lips of the new
brakes, tighten the hub nut to the specified torque. bearing assembly.
(8) Install the hub nut retainer and a new
split NOTE: Ensure that (he inside of the outer
pin to the drive shaft. race of the bearing is precoated with wheel
(9) Check the hub end float as described later in bearing grease. If necessary, pack the outer
this section. race of the wheel bearing with wheel bearing
(10) Install the front wheel and lower the vehicle grease after it is installed to the steering
to the ground. knuckle.
(2) Using the press and press plates, support the
TO DISMANTLE steering knuckle with the outside face uppermost.
NOTE: The front wheel bearing assembly is Using a suitable diameter steel tube that contacts on
non-serviceable. If the wheel bearing is dis- the outer race only, press the outer race full into the
mantled for any reason it should be re- steering knuckle.
newed. (3) Install the snap ring to the groove in the
steering knuckle.
(1) Remove the steering knuckle from the vehi- (4) Install the inner races to the steering
cle as previously described. knuckle
(2) Hold the steering knuckle assembly in a vice and support the inner race on the press using a
with soft jaw guards. suitable tube or mandrel.
(3) Using a hammer and a suitable pipe or tube (5) Using the press and a suitable tube press the
that pushes on the inside of the hub, drive out the hub assembly into the steering knuckle. When using
wheel hub and outside inner race from the steering the press ensure that the pressing force does not
knuckle assembly. exceed 29 kN.
(4) Using snap ring pliers, remove the snap ring (6) With the press exerting a force of 44.1 kN
that retains the outer bearing race from the wheel side rotate the steering knuckle from side to side several
of the steering knuckle. turns to ensure that the wheel bearings are operating
(5) Using a suitable press and press plates, smoothly.
support the steering knuckle with the outside face (7) Install the steering knuckle to the vehicle
downwards. To aid in dismantling, position the inside as
inner race in the bearing and press the assembly from previously described.
the steering knuckle. Discard the bearing assembly.
(6) Using a bearing puller and a press, remove TO CHECK HUB END FLOAT
the inner race from the hub assembly.
If the inner race cannot be removed from the hub (1) Raise the front of the vehicle and support it
in this manner, it may be necessary to grind the race on chassis stands. Remove the front wheel.
(2) Mount the dial gauge on the steering knuckle
so that the dial gauge plunger is against the wheel hub.
(3) Zero the dial gauge and attempt to move the
hub in and out. Total hub end float should not exceed
0.05 mm.
(4) Renew the wheel bearing as previously de-
scribed if necessary.
4. SUSPENSION UNIT
Special Equipment Required:
To Dismantle — Spring compressor
TO REMOVE AND DISMANTLE
(1) Raise the front of the vehicle and support it
Dismantled view of the steering knuckle and hub on chassis stands. Remove the front wheels.
components.
160 Front Suspension
the ball joint or bushes as described later in this NOTE: Ensure that the bush is installed
section. with the flat portion in its original location.
Installation is a reversal of the removal procedure (3) To remove the front control arm bush use a
with attention to the following points: suitable tube that pushes on the outer circumference
(1) When installing the control arm bush of the bush and a split tube supporting the control
bracket, ensure that the protrusion on the bracket is arm.
towards the inside of the vehicle. (4) After the bush has been pressed out approx-
(2) Do not fully tighten the control arm bush imately half way, cut the protruding part of the bush
bolts and through bolt nut until the curb weight of the using a hacksaw. Cutting the bush in this way will
vehicle is on the suspension. allow removal.
NOTE: Curb weight is with the vehicle (5) Support the control arm and push the new
bush in from the outside using a suitable tube that
unladen except for a full tank of fuel and pushes on the outer circumference only.
normal amounts of oil and water and with (6) Install the control arm to the vehicle as
the spare lyre, jack and hand tools in their previously described.
normal positions.
(3) Tighten the ball joint nut to the specified
torque and retain with a new split pin. 6. STABILISER BAR
TO CHECK AND RENEW BALL JOINT TO REMOVE AND INSTAL
(1) Remove the control arm from the vehicle as (1) Raise the front of the vehicle and support it
previously described. on chassis stands.
(2) Install the ball joint nut and turn the ball (2) Remove the bolts at the flexible joint retain-
joint at least ten revolutions to ensure that the ball ing the front engine pipe to the exhaust pipe located
joint is correctly seated. below the stabilizer bar.
(3) Using a spring scale with the hook placed (3) Remove the bolt from the exhaust pipe
over the split pin hole, check the ball joint swinging mounting below the stabilizer bar. Disconnect the
torque. A new ball joint should measure 15.7-80.4 N exhaust pipe at the flexible joint and allow the front of
and a used ball joint should measure 7.8-80.4 N. the pipe to hang down.
Renew the ball joint if necessary. (4) Remove the stabilizer bar bracket retaining
(4) Using a small torque wrench or preload bolts and remove the stabilizer bar brackets from the
gauge, measure the force required to rotate the ball vehicle.
joint. A new ball joint should measure between (5) Remove the stabilizer bar lower link nuts
1.0-4.9 Nm and a used ball joint should measure from each control arm. When removing the lower nuts
between 0.5-4.9 Nm. Renew the ball joint if neces- it may be necessary to hold the upper nuts with a
sary. spanner.
(5) To renew the ball joint, remove the snap ring (6) Maneuver the stabilizer bar from the
from the stud end of the ball joint using snap ring vehicle.
pliers. Installation is a reversal of the removal procedure
(6) Support the control arm in a press, ball joint with attention to the following points:
stud uppermost, with a suitable tube that is large (1) Ensure that the stabilizer bar mounting rub-
enough for the ball joint to pass through. bers are in a serviceable condition and secure in the
(7) Press the ball joint out from the control arm. mounting brackets.
(8) Press a new ball joint into the control arm
using a suitable tube that pushes on the outer circum-
ference of the joint only.
(9) Install the snap ring and install the
control
arm to the vehicle as previously described.
REAR SUSPENSION
2. DESCRIPTION
The independent type rear suspension consists of
a suspension unit, a knuckle assembly which incorpo-
rates the stub axle, inboard control arms and a
stabilizer bar.
The suspension unit consists of a sealed, oil filled
shock absorber, enclosed at the upper end by a coil
spring on which an upper mounting assembly is
located and attached to the body.
The shock absorber piston rod is attached to the
centre of the suspension unit upper mounting assem-
bly.
The lower end of the suspension unit is attached
to the knuckle assembly to which the brake caliper
Checking the rear control arm outer pivot bolt for and/or the brake backing plate is mounted.
security. The control arms are attached to the knuckle
assembly at the outer end, and the crossmember at the
(5) Loose or worn control arm bushes or pivot inner end.
bolts: Check and tighten or renew the worn compo- The stabilizer bar is attached to the knuckle
nents. assembly and mounted to the underbody. As well as
NOTE: Check the serviceability of the sus- reducing body roll when cornering it also secures the
pension units, control arm bushes and pivot knuckle assembly, preventing fore and aft movement.
bolts as previously described. Adjustment of the toe out is provided by a
If incorrect rear wheel alignment is sus- graduated cam mounted on the rear control arm inner
pected, it is recommended that the vehicle be pivot bolt. Each graduation on the cam is equivalent
taken to a wheel alignment specialist or a to 2 mm adjustment.
Nissan dealer to be checked and if necessary Camber is set in production and cannot be
adjusted. adjusted. If the camber is not within Specifications,
Visually inspect the stabilizer bar for inspect the suspension components and renew the
damage. damaged or worn components as necessary.
3. REAR HUB caliper and tighten the retaining bolts to the torque
specified in the Brakes section. Install the brake hose to
Special Equipment Required the suspension unit and secure with the retaining clip.
To Check Hub Bearing End Float — Dial gauge
To Renew Bearing — Press and suitable drift TO RENEW BEARING
(1) Remove the rear hub as previously de-
TO REMOVE AND INSTAL scribed.
(1) Raise the rear of the vehicle and support it (2) Remove the snap ring from the rear of the
on chassis stands. Remove the rear wheel and release hub assembly.
the handbrake. (3) Support the rear of the hub around the
(2) On models with rear drum brakes, proceed bearing housing, ensuring that the bearing will not be
to operation (6). obstructed when being pressed out.
(3) Remove the clip securing the brake hose to (4) Using a suitable drift, press the bearing out
the suspension unit and disengage the hose. of the hub.
(4) Remove the bolts securing the brake caliper
to the knuckle assembly.
(5) Slide the caliper from the disc and support it
away from the working area, ensuring that no excess
strain is placed on the brake hose.
(6) Rotate the hub and check that it rotates
smoothly. If it does not rotate smoothly, renew the
hub bearing.
(7) Mount a dial gauge with the plunger posi-
tioned against the outer face of the hub. Move the hub
back and forth in line with the stub axle and note the
reading on the dial gauge. If the end float exceeds
Specifications, renew the hub bearing.
(8) Remove the hub grease cap from the rear
hub.
(9) Remove the split pin from the stub axle and
remove the nut retainer, the hub retaining nut and
washer. Remove the hub assembly from the stub axle.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Tighten the hub retaining nut to the specified
torque. Dismantled view of the rear hub assembly. Drum brake
(2) Check the hub bearing end float as previ- model.
ously described.
(3) On models with disc brakes, install the brake
4. SUSPENSION UNIT
Special Equipment Required:
To Dismantle — Spring compressor
NOTE: If a coil spring is defective it is the suspension unit ensuring that the flat end of the
advisable to renew both coil springs as a spring is positioned at the top and the lower end of the
matched set. spring is located correctly in the suspension unit.
(2) Install the remaining components to the sus-
(13) Check the spring seat for cracks, deforma- pension unit, ensuring that the arrow on the spring
tion or wear and renew as necessary. seat will be facing the stub axle when installed.
(14) Check the upper mounting and the insulator (3) Install a new upper mounting retaining nut,
for wear, damage, signs of melting rubber or deterio- tighten to the specified torque and remove the spring
compressor.
ration. (4) Position the suspension unit inside the rear
(15) Check that the piston rod is not cracked, wheel housing and maneuver the mounting studs
bent or damaged. into position. With the aid of an assistant, install the
suspension unit retaining nuts and tighten to the
specified torque.
5. CONTROL ARM
Special Equipment Required:
To Renew Control Arm Bush — Press and suitable
removal tool
TO REMOVE AND INSTAL
(1) Raise the rear of the vehicle and support it
on chassis stands as described in the Wheels and Tires
section.
(2) Suitably mark the front and rear control
arms to ensure installation to the original locations.
NOTE: The front and rear control arms are
identical in appearance, however, on models
manufactured prior to March 1988 the
compound of the rubber bushes differ.
(3) Remove the nut and bolt securing the control
arms to the knuckle assembly.
(4) Suitably mark the rear inner pivot bolt cams
in relation to the crossmember to ensure correct
installation. Dismantled view of the control arms and associated
(5) Remove the rear control arm inner pivot components. Disc brake model.
bolt, adjusting cam, nut and control arm from the
vehicle. cams and the crossmember that were made prior to
(6) Remove the front control arm inner pivot removal. Install the inner pivot bolt nuts but do not
bolt, washer, nut and control arm from the vehicle. tighten.
(7) Inspect the control arm bushes for wear, (3) Install the bolt that secures the control arms
to the knuckle assembly and tighten the nut finger
cracks and deterioration and renew as necessary. tight.
(8) Inspect the control arms for cracks, damage (4) Lower the vehicle to the ground. With the
and distortion and renew as necessary. weight of the vehicle on the rear wheels, ensure that
(9) Inspect the pivot bolts for damage and renew the marks on the inner pivot bolt cams and the
as necessary. crossmember are aligned.
Installation is a reversal of the removal procedure (5) Tighten the inner and outer control arm
with attention to the following points: bolts and nuts to the specified torque.
(1) Install the control arms to the original (6) Check and if necessary adjust the rear wheel
loca- alignment. Refer to the Rear Wheel Alignment head-
tions, ensuring that the inner pivot bolts are installed ing in this section.
from the front of the crossmember.
TO RENEW CONTROL ARM BUSH
(1) Remove the control arm as previously de-
scribed.
(2) Using a press and press plates or a bush
removal tool, remove the bush from the control arm.
NOTE: If a press or bush removal tool is not
available, a simple alternative can be made
using a long bolt, large and small washers, a
nut and a tubular spacer. This method is
illustrated in the General Information sec-
tion under the General Repair Procedures
heading.
(3) Install a new bush to the control arm
ensuring
that it is pressed squarely into the control arm. When
installed, the bush should be equidistant from either
Ensure that the cam and the crossmember are suitably end of the control arm bore.
marked prior to loosening the nut. (4) Install the control arm as previously de-
(2) Align the marks on the rear inner pivot bolt scribed.
170 Rear Suspension
6. KNUCKLE ASSEMBLY pipe to the wheel cylinder and tighten the flare nut
securely.
TO REMOVE AND INSTAL (6) Install the rear hub as previously described.
(7) On drum brake models, bleed the brake
(1) Remove the rear hub as previously de- hydraulic system as described in the Brakes section.
scribed. (8) With the weight of the vehicle on the road
(2) On drum brake models, disconnect the brake wheels, tighten the control arms retaining bolt and nut
pipe from the wheel cylinder and plug the cylinder and the stabilizer bar retaining nut to the specified
and brake pipe apertures to prevent the loss of brake torque.
fluid and the entry of dirt. (9) Check and if necessary adjust the rear wheel
(3) Remove the backing plate retaining bolts and alignment. Refer to the Rear Wheel Alignment head-
remove the backing plate from the knuckle assembly. ing in this section.
(4) Remove the nut and bolt securing the control
arms to the knuckle assembly.
(5) Remove the bolts and nuts securing the
suspension unit to the knuckle assembly. 7. STABILISER BAR
(6) Remove the nut, washers and bush securing
the stabilizer bar to the knuckle assembly, rotate the TO REMOVE AND INSTAL
knuckle assembly and remove it from the stabilizer
bar. (1) Raise the rear of the vehicle and support it
(7) Carefully clean the knuckle assembly. Do not on chassis stands as described in the Wheels and Tires
immerse the rubber bush in solvent as damage will section. Remove the rear wheels.
occur. (2) Remove the nut. washer and bush retaining
(8) Check the knuckle assembly for wear, cracks the stabilizer bar to each knuckle assembly.
and damage. (3) Remove the bolts retaining the intermediate
Installation is a reversal of the removal procedure exhaust pipe to the rear of the catalytic converter,
with attention to the following points: remove the bolt securing the exhaust mounting to the
(1) Install the knuckle assembly onto the stabi- underbody and slightly lower the intermediate exhaust
liser bar, maneuver it into position with the suspen- pipe. Support the intermediate pipe to prevent the
sion unit and install the retaining bolts and nuts. tailpipe contacting the lower bumper panel.
Tighten the bolts and nuts to the specified torque. (4) Remove the bolts retaining the stabilizer bar
(2) Install the control arms to the knuckle mounting brackets to the underbody and withdraw
assem- the stabilizer bar from each knuckle assembly. Ma-
bly and install the retaining bolt and nut. Do noeuvre the stabilizer bar from the vehicle.
not (5) Remove the mounting rubbers from the
tighten the retaining bolt and nut at this stage. stabilizer bar and the rubber bush and spacer from
(3) Install the bush, washers and retaining nut to each knuckle assembly.
the stabilizer bar. Do not tighten the retaining nut at (6) Inspect the stabilizer bar for cracks and
this stage. damage and renew as necessary.
(4) Install the backing plate to the knuckle as-
sembly and tighten the retaining bolts to the specified (7) Inspect the stabilizer bar mounting brackets
torque. for wear and damage and renew as necessary.
(5) On drum brake models, connect the brake (8) Inspect the mounting rubbers, the rubber
bushes and spacers for wear and deterioration and
renew as necessary.
View of the knuckle assembly removed from the View of the stabilizer bar mounting bracket and rubber
vehicle. Disc brake model. removed from the stabilizer bar.
Rear Suspension 171
Installation is a reversal of the removal procedure Place a vertical mark at the chalk line in the
with attention to the following points: centre of each tire.
(1) When installing the stabilizer bar to the (4) Using a telescopic gauge or tape measure,
knuckle assembly bushes, ensure that the thicker bush measure the distance between both vertical marks and
is installed to the front of the knuckle assembly. Install record the measurement.
the rear bush, washers and nut but do not tighten at (5) Move the vehicle forward until the marks are
this stage. to the front of the suspension, with the horizontal
(2) Install the stabilizer bar mounting marks at the same height as in operation (3).
brackets, (6) Measure the distance between both vertical
ensuring that the end with the large bevel is facing the marks.
front of the vehicle. Tighten the retaining bolts to the (7) The difference between the two measure-
specified torque. ments will be the amount of toe out of the rear wheels.
(3) Using a new gasket, install the intermediate (8) If the toe out is not as specified, adjust the
exhaust pipe to the catalytic converter, ensuring that rear control arm cams as follows:
the earth wire terminal is installed, and tighten the (9) Measure the distance between the inner
bolts securely. Install the exhaust mounting wheel rim and the adjusting flange on the rear
retaining crossmember. Measure the distance on the other side
bolt. of the vehicle in the corresponding positions.
(4) Install the rear wheels and lower the (10) If the measurements are equal, loosen the
vehicle cam nut and turn the cam bolt to move the rear
to the ground. With the weight of the vehicle on the control arm half the distance required to bring the
road wheels, tighten the stabilizer bar retaining nuts to rear wheel toe out to specifications. Repeat this
the specified torque. operation on the other side of the vehicle.
(11) If the measurements obtained in operation
8. REAR WHEEL ALIGNMENT (9) are not equal, proceed as follows:
Specialized equipment is required to measure the (a) If the toe out is less than specifications,
rear wheel alignment. It is therefore recommended decrease the length of the shorter arm.
that the vehicle be referred to a specialist suspension (b) If the toe out is greater than specifications,
workshop or an authorized dealer for measurement increase the length of the longer arm.
and adjustment. The suspension components should NOTE: The toe out will alter approximately
be inspected and renewed as necessary prior to having 2 mm with each graduation of the adjusting
the wheel alignment checked. If any suspension com- cam.
ponents are renewed, the rear wheel toe out may be
temporarily adjusted as described below.
TO INSPECT
Examine the tread of the tires. Excessive or
uneven wear will indicate misalignment or damaged
or worn components. Refer to the Tire Wear Trouble
Shooting Chart in the Wheels and Tires section for
possible causes and renew the faulty components.
Badly worn tires should be renewed prior to
having the wheel alignment checked.
TO CHECK AND ADJUST TOE OUT
NOTE: The following procedures are only a
temporary measure. The vehicle should be
referred to a specialist suspension work-
shop or authorized dealer for accurate
measurement and adjustment.
(1) Position the vehicle on a level floor and
bounce the vehicle several times to settle the suspen-
sion.
(2) Move the vehicle forward approximately 5
meters, with the front wheels straight ahead, to settle
the tires and suspension to the normal running
position. Diagram indicating rear wheel toe out. B should be less
(3) Place a chalk line across both tire treads at a than A. Refer to Specifications.
point equivalent to the stub axle height and to the rear
of the suspension.
172
BRAKES
A pressure proportioning valve is incorporated in (2) Raise the bonnet and install covers to
each circuit to prevent premature locking of the rear both
wheels during severe braking. the front mudguards. Cover the areas of paintwork
The four wheel hydraulically operated brakes beneath the master cylinder with absorbent cloth.
utilize disc brakes on each front wheel and disc brakes (3) Disconnect the wiring from the pressure
or leading and trailing drum brake shoes on each rear sensing switch.
wheel. (4) Disconnect the brake pipes from the master
The front disc brakes comprise a disc attached to cylinder and plug the outlets and pipes to prevent the
the hub assembly and a caliper bolted to the steering loss of fluid and the ingress of dirt.
knuckle. (5) Remove the nuts retaining the master cylin-
The rear disc brakes comprise a disc and hub der to the brake servo unit and remove the master
assembly attached to the rear stub axle and a caliper cylinder from the vehicle.
and anchor plate bolted to the backing plate.
The front and rear calipers are of the sliding type. TO DISMANTLE
As pad wear takes place, the caliper piston is allowed (1) Remove the master cylinder as previously
to slide outwards through the seal to take up a new described.
position in the caliper bore. Elastic deformation of the (2) Remove the reservoir cap and diaphragm,
seal takes place when the brakes are applied, which drain and discard the brake fluid from the reservoir.
returns the piston slightly when the brakes are re- (3) Carefully remove the reservoir from the
leased. Thus a constant clearance is maintained master cylinder by pulling it from the reservoir
between the pads and the disc when the brakes are in retainers by hand. Remove and discard the retainers
the off position. from the master cylinder.
The disc brakes do not require periodical adjust- (4) Using internal snap ring pliers, remove the
ment in service to compensate for pad wear as they snap ring from the primary reservoir port.
are self adjusting. (5) Remove the fast fill valve assembly and the
The leading and trailing shoe drum brakes on the O ring from the port. Remove and discard the valve
rear wheels use a double ended wheel cylinder to washer from the fast fill valve.
operate both brake shoes at the top. The lower end of (6) Remove the proportioning valve plugs and
each brake shoe abuts a fixed anchor point. The brake the O rings. Discard the O rings. Withdraw the springs
shoes are automatically adjusted when the brakes are and valve plungers from the master cylinder. Remove
operated. and discard the seals from the valve plungers.
The handbrake operates the rear brakes via a (7) Remove the pressure sensing switch and
cable arrangement. lever assembly from the master cylinder.
{8) Remove the cylinder end plug from the
master cylinder. Remove and discard the O ring from
3. MASTER CYLINDER the plug.
(9) Carefully tap the front of the master cylinder
Special Equipment Required: vertically on a block of wood and remove the pressure
To Install New Seals — Suitable machined drift differential pistons from the master cylinder. Remove
and discard the O rings from the pistons.
TO REMOVE (10) Push the primary piston forward in the
cylinder with a blunt rod and while holding the
(1) Depress the brake pedal several times to pressure, remove the stop pin from the master cylin-
deplete the vacuum from the system. der.
(11) The primary piston may now be withdrawn
from the cylinder bore. The secondary piston, retainer
and spring can also be withdrawn by carefully tapping
the master cylinder on a block of wood.
(12) Prise the legs of the seal retainer upwards
and remove it from the primary piston. Remove the
seal and guide. Discard the seal and retainer.
NOTE: The secondary piston must no! be
dismantled by removing the screw. This
assembly has a factory preset length and the
screw must not be altered in service.
(13) Remove the main seal and the guide from
Installed view of the master cylinder and servo unit. Air the front of the secondary piston. Stretch the rear seal
duct removed for clarity. 1.8 liter model. from the groove and remove it from the piston. Take
176 Brakes
care not to damage the piston surfaces where the inner (4) Discard all rubber parts and if applicable, the
diameter of the piston seals locate. piston assemblies.
(14) Remove the garter springs, back up rings, NOTE: Where possible use a genuine major
seals and the retainer from the master cylinder, noting
the installed direction of the seals to aid assembly. repair kit which contains pre-assembled rub-
ber seals and pistons when overhauling a
NOTE: It is important that care is taken not master cylinder. The use of a major kit will
to damage the bore surface or the seal ensure a thorough overhaul and long service
surfaces during removal of these parts. Note from the unit.
the order and direction during removal,
(15) Remove the external O ring from the master TO ASSEMBLE
cylinder body. (1) Liberally coat the cylinder bore and all
internal parts with clean brake fluid.
TO CLEAN AND INSPECT
NOTE: Install all parts supplied with the
(1) Wash all components thoroughly in methyl- repair kit.
ated spirits. Do not use petrol, kerosene or other
cleaning solvents. (2) Install the seal retainer in the mouth of
(2) Check the master cylinder bore for wear, the
scoring or pitting. master cylinder, small diameter first.
(3) Install the seal, in the direction rioted
NOTE: Do not hone the master cylinder on
bore. If the bore is pitted or worn, renew the removal, against the seal retainer, followed by the first
master cylinder as an assembly. back up ring, large diameter first.
(3) Ensure that all the inlet and compensating (4) Install the garter spring against the back up
ports between the reservoir and the cylinder bore are ring. Insert a machined drift into the bore and lightly
free of any obstructions. push the garter spring into its locating groove.
(5) Install the remaining seal, in the
direction
noted on removal, against the garter spring already
BACK UP RING
installed. Install the second back up ring, large (22) Install the fast fill valve assembly in
diam- the
eter first. primary reservoir port (nearest to the mounting flange
(6) Install the second garter spring. Insert of the master cylinder) and install the snap ring
a to
machined drift into the bore and lightly push the retain the assembly. Ensure that the snap ring is
garter spring into its locating groove. correctly seated in the groove.
(7) Smear the secondary piston with clean brake (23) Smear the new reservoir retainers with clean
fluid. Ease the seal over the piston body into the brake fluid and install them into the reservoir ports.
groove adjacent to the spring, ensuring that the seal lip Carefully press the brake fluid reservoir into position,
faces the spring and that the nylon spacer is against ensuring that the outlet extensions are fully inserted in
the back of the seal. the reservoir retainers.
(8) Install the guide onto the secondary (24) Install the reservoir cap insert to the dia-
piston, phragm and press the cap assembly onto the reservoir.
large internal diameter first, followed by the main seal
with the lip facing away from the spring. TO INSTAL
(9) Lubricate the secondary piston assembly
with clean brake fluid and install the secondary spring Installation is a reversal of the removal procedure
and retainer to the piston. Install the complete assem- with attention to the following points:
bly into the master cylinder bore. (1) Pour a small amount of clean brake fluid into
(10) Smear the primary piston with clean brake the reservoir and pump the master cylinder pistons
fluid. Install the guide, large internal diameter first, with a blunt rod until fluid begins to emerge from the
followed by the main seal with the lip facing towards outlets.
the small end of the piston. (2) Install the master cylinder to the brake servo
(11) Install the retainer to the spigot on the front unit and loosely install the master cylinder retaining
end of the primary piston ensuring that the legs of the nuts.
retainer engage with the groove on the piston. (3) Connect the brake pipes to the master cylin-
(12) Lubricate the primary piston assembly with der outlets, but do not tighten at this stage.
clean brake fluid and install the assembly into the (4) Securely tighten the nuts retaining the master
master cylinder bore. With a blunt rod, push the cylinder to the brake servo unit.
assembly down the bore sufficiently to preload the (5) Securely tighten the brake pipes and connect
pistons. While holding the preload, install the stop pin the wiring to the pressure sensing switch.
and valve assemblies into (6) Fill the master cylinder reservoir with clean
the master cylinder body and tighten securely. brake fluid and bleed the brakes as described under
(13) Install a new O ring to the groove on the boss the Hydraulic System heading.
of the mounting flange of the master cylinder. (7) Check and if necessary adjust the brake
(14) Install new O rings to the pressure differential pedal height and free play as described under the
pistons, smear them with clean brake fluid and install Brake Pedal heading.
them into the master cylinder body.
(15) Install a new O ring to the pressure differen-
tial end plug, install the plug to the master 4. BRAKE SERVO UNIT
cylinder
body and tighten to the specified torque. TO CHECK OPERATION
(16) Using a blunt probe entered through the
sensing switch location hole, separate the pressure (1) With the engine switched off, apply the
differential pistons and install the switch actuating footbrake several times to exhaust all vacuum from
lever between them. the system.
(17) Screw the sensing switch into its locating (2) Apply the footbrake and hold the brake pedal
hole until the detents on the switch body just contact fully depressed.
the locating hole facing (with the radial grooves). (3) Start the engine. If the servo unit is function-
Screw the switch assembly in a further half to one full ing satisfactorily a distinct downward movement of
turn ensuring that the detents locate in the grooves. the
(18) Install new valve seals to the proportioning brake pedal should be noticed.
valve plungers, with the serrations of the seals facing Should the pedal fail to move downward when the
away from the hexagons of the plungers. engine has been started, the vacuum system can be
(19) Install the new O rings to the
proportioning considered inoperative.
valve plugs. NOTE: If the pedal continues to fall away
(20) Install the valve springs over the stems of the there is a fault in the hydraulic system.
proportioning valves, insert the install the valve
plugs. (4) Ensure that the brake pedal is fully released,
Tighten the plugs to the specified torque. start the engine and run it at medium speed. Stop the
(21) Install a new O ring to the base of the fast fill engine.
valve assembly. Install a new valve washer to the base
of the valve.
178 Brakes
TO TEST ONE WAY CHECK VALVE View of the brake servo unit and associated compo-
(1) Disconnect the hose and remove the check nents.
valve from the servo unit. (5) Remove the master cylinder as described
(2) Check the valve for sticking. Suction on the under the Master Cylinder heading.
manifold side should allow air to flow freely. Air (6) Working inside the vehicle, remove the clip
blown into the valve from the manifold side should and clevis pin connecting the pushrod to the brake
not be able to flow through the valve. pedal.
(3) Install the valve and check the operation (7) Remove the nuts retaining the servo unit to
of the bulkhead and maneuver the servo unit and
the servo unit as previously described. spacer block from the vehicle.
NOTE: Check that there are no air leaks at
the hose connections and that the hose clips TO INSTAL
are tight. Also check that the hose is not Installation is a reversal of the removal procedure
bulged or collapsed due to deterioration. with attention to the following points:
(1) With the servo unit and master cylinder
installed to the vehicle, bleed the hydraulic system as
described under the Hydraulic System heading.
(2) Check and if necessary adjust the brake
pedal height and free play as described under the
Brake Pedal heading.
5. FRONT BRAKES
Special Equipment Required:
To Check Disc Runout — Dial gauge
To Check Disc Thickness — Micrometer
TO CHECK AND RENEW BRAKE PADS
(1) Raise the front of the vehicle and place it on
chassis stands. Remove the front wheels.
(2) Inspect the brake pads on both sides of the
Checking for vacuum at the servo unit. The engine vehicle. If the friction material on one or more of the
must be running for this test. pads is less than 2 mm thick or contaminated with
fluid or grease, renew the brake pads as a set as
TO REMOVE follows.
(1) Raise the bonnet and install covers to both NOTE: If the brake pads are contaminated,
front mudguards. trace and rectify the cause prior to installing
(2) On 1.6 liter models, remove the air cleaner the new set of pads.
assembly from the vehicle. If necessary refer to the
Fuel System section. (3) Drain approximately two thirds of the brake
(3) On vehicles equipped with power steering, fluid from the master cylinder reservoir. This can be
remove the reservoir from the bulkhead and move it done by loosening the bleeder valve on the caliper and
to one side. If necessary refer to the Steering section. allowing the fluid to drain into a container. Discard
(4) Disconnect the vacuum supply hose from the this fluid.
servo unit.
Brakes 179
CALIPER
To Remove and Install
(1) Raise the front of the vehicle and place it on
chassis stands. Remove the relevant front wheel.
(2) Remove the brake hose retaining bolt and
plug the hose to prevent the loss of fluid and the
ingress of dirt.
(3) Remove the bolts retaining the caliper an-
chor plate to the steering knuckle and slide the caliper
off the disc.
the caliper body. Plug the brake hose to prevent the (4) Locate the dust seal in the groove of the
loss of fluid and the ingress of dirt. Remove and caliper body and install the retaining clip.
discard the sealing washers. (5) Lubricate the guide bolts using a suitable
(3) Remove the guide bolts and slide the caliper grease. Install the caliper body to the anchor plate and
body from the anchor plate and pad assembly. install and tighten the guide bolts to the
(4) Remove the piston dust cover retaining clip. specified
Remove and discard the dust cover. torque.
(6) Replenish the master cylinder reservoir with
the recommended fluid and bleed the brakes as
described under the Hydraulic System heading.
(7) Install the front wheels and lower the vehicle
to the ground.
(8) Road test the vehicle and check for correct
brake operation.
BRAKE DISC
To Check Runout
(1) Raise the front of the vehicle and support it
on chassis stands. Remove the relevant front wheel.
(2) Install the wheel nuts with the flat side of
the
wheel nut towards the disc. Lightly tighten the nuts to
BRAKEPAD BRAKE PAD secure the disc against the hub.
Dismantled view of the front brake caliper.
To Inspect
(1) Inspect the machined faces of the disc for
scores, cracks, wear and signs of overheating. Renew the rear brake pads if the friction material is less
(2) Using a micrometer, measure the thickness than 2 mm thick.
of the disc at several positions around the face of the
disc. Renew the disc if the minimum thickness is (2) Inspect the brake pads on both sides of the
below Specifications. vehicle. If the friction material on one or more of the
pads is less than 2 mm thick or contaminated with
fluid or grease, renew the brake pad as a set as follows.
NOTE: If the brake pads are contaminated
trace and rectify the cause prior to installing
the new set of pads.
(3) Drain approximately two thirds of the brake
fluid from the master cylinder reservoir. This can be
done by loosening the bleeder valve on the caliper and
allowing the fluid to drain into a container. Discard
this fluid.
NOTE: Do not drain all the fluid from the
reservoir otherwise it will be necessary to
bleed the hydraulic system. The fluid is
drained from the reservoir to prevent over-
flow when the caliper piston is pushed back
into the caliper bore to facilitate pad re-
Inspect the brake discs for scoring and wear.
newal.
(3) If the disc thickness is satisfactory but the (4) Remove the guide bolts and lift the caliper
disc is scored, machine equal amounts from the body clear of the disc.
machined face on each side of the disc, to restore the NOTE: Do not allow the caliper to hang on
serviceability of the disc. the brake hose.
NOTE: Disc machining is best entrusted to (5) Noting the installed positions, remove the
a reliable brake specialist who can advise on brake pads, shims and spring clips from the anchor
disc serviceability. plate.
(6) Using a pair of long nosed pliers with the
6. REAR DISC BRAKES nose located in the recesses of the piston, rotate the
Special Equipment Required:
piston clockwise to retract it into the cylinder body.
Align the recesses between the brake pad retaining
To Check Disc Runout — Dial gauge lugs on the caliper body. Refer to the illustration.
To Check Disc Thickness — Micrometer (7) If necessary, check the disc runout and
thickness as described under the Brake Disc heading.
TO CHECK AND RENEW BRAKE PADS (8) Ensure that the guide bolts move freely in the
(1) Raise the rear of the vehicle and place it on caliper body and that the dust boots are in good
chassis stands. Remove the rear wheels. condition.
182 Brakes
To Dismantle To Assemble
(1) Raise the rear of the vehicle and place it on (1) Lubricate the cam bearing with multipurpose
chassis stands. Remove the relevant rear wheel. grease and install the seal.
(2) Remove the brake hose retaining bolt from (2) Install the cam and cam lever to the
the caliper body and plug the hose to prevent the loss caliper
of fluid and the ingress of dirt. body. Install the cam lever spring, washer and nut, and
(3) Remove the handbrake cable bracket retain- tighten the nut to the specified torque.
ing bolt and disconnect the handbrake cable from the (3) Install a new O ring to the pushrod and
cam lever. install
(4) Remove the guide bolts and slide the caliper the link, pushrod, key plate, spring and spring cover to
body off the pads. the caliper body. The key plate must engage the caliper
(5) Using a pair of long nose pliers with the nose body. Secure the assembly with the snap ring.
located in the recesses of the piston, rotate the piston (4) Dip a new piston seal in clean hydraulic brake
anticlockwise to remove it from the caliper body. fluid. Insert the seal into the groove in the caliper bore
(6) Remove the dust cover retaining clip and dust ensuring that the seal is correctly seated and not
cover. Discard the dust cover. twisted.
(7) Using a thin blunt probe, preferably made (5) Install a new dust cover to the piston prior
from wood or plastic, remove and discard the piston to
seal from the groove in the caliper bore. installing the piston to the caliper bore.
(8) Using internal snap ring pliers, remove the (6) Coat the piston and caliper bore with clean
snap ring from the caliper bore. hydraulic brake fluid and using long nose pliers rotate
(9) Withdraw the spring cover, spring, key plate, the piston clockwise into the caliper bore.
pushrod and link from the caliper bore. Do not mix (7) Locate the dust seal in the groove of the
these components from the left and right hand sides as caliper body and install the retaining clip.
they differ. (8) Lubricate the guide bolts using a suitable
(10) Remove and discard the O ring from the grease. Install the caliper body and tighten the guide
pushrod. bolts to the specified torque.
(11) Remove the spring, nut and washer from the (9) Replenish the master cylinder reservoir with
cam lever. Remove the cam lever and cam from the the recommended fluid and bleed the brakes as
caliper body. described under the Hydraulic System heading.
(12) Remove the cam seal from the caliper using a (10) Install the rear wheel and lower the vehicle to
screwdriver. the ground.
(13) Clean all the caliper components in methy- (11) Road test the vehicle and check for correct
lated spirits and arrange the components in order on a brake operation.
clean dry surface to aid assembly.
BRAKE DISC
To Inspect
(1) Inspect the caliper bore and piston for pit- To Check Runout
ting, wear or damage. Renew the caliper assembly or (1) Raise the rear of the vehicle and support it on
piston if damage is evident. chassis stands. Remove the relevant rear wheel.
(2) Mount a dial gauge stand to a suspension
NOTE: Slight rust spots in the caliper bore component and position the dial gauge plunger
may be removed with fine emery paper. The against the wheel hub. Check that the end float is less
piston must not be polished as the plated
surface will be damaged.
(2) Inspect the guide bolts for wear or damage
and renew as necessary.
(3) Inspect the threads of the pushrod for wear or
damage and renew as necessary.
(4) Inspect the nut inside the piston for wear,
damage and security. Renew the piston if any damage
is evident.
(5) Inspect the cam for wear, damage or pitting,
renew as necessary.
(6) Inspect the cam bearing in the caliper body
for wear, damage or pitting and renew the seal and
bearing as necessary.
(7) Inspect the guide bolt rubbers for deteriora-
tion, wear or damage. Renew as required.
To Inspect
(1) Inspect the machined faces of the disc for
scores, cracks, wear and signs of overheating.
(2) Using a micrometer, measure the thickness
of the disc at several positions around the face of the
disc. Renew the disc if the minimum thickness is
below Specifications.
(3) If the disc thickness is satisfactory but the
disc is scored, machine equal amounts from the
machined face on each side of the disc, to restore the
serviceability of the disc. Installed view of the left hand side rear drum brake
components.
Brakes 185
(6) Using a suitable pair of pliers, disengage the (5) Inspect the springs and handbrake lever for
upper and lower return springs from the leading shoe, fatigue and distortion. Renew as required.
and then remove them from the trailing shoe. (6) Operate the handbrake lever and check for.
(7) Using a pair of pliers, compress the leading smooth operation of the handbrake cable. Renew as
shoe retainer, turn through ninety degrees and remove required under the Handbrake Cable and Lever
the retainer, spring and pin. Remove the leading shoe Assembly heading.
from the backing plate. (7) Check the bleeder valve for blockage.
(8) Using the same procedure, remove the trail- (8) Clean and lubricate the adjuster rod.
ing shoe retainer. (9) Clean and inspect the backing plate for
(9) Lift the trailing shoe from the backing plate cracks, damage and wear. Renew as required.
and disconnect the handbrake cable from the hand-
brake lever. Remove the trailing shoe assembly from TO ASSEMBLE AND INSTAL
the backing plate.
(10) If the brake shoes are to be renewed, remove (1) If the wheel cylinder was overhauled, pro-
the C clip from the trailing shoe and remove the ceed as follows:
handbrake lever assembly. (a) Lubricate the pistons and seats with brake
(11) If the wheel cylinder is to be overhauled, fluid and install the seals onto the pistons so that the
proceed as follows: lip on the seals will be facing towards the centre of the
(a) Disconnect the brake pipe from the rear of cylinder.
the wheel cylinder and plug the pipe to prevent the (b) Install the spring, pistons and rubber boots to
loss of fluid and the ingress of dirt. the wheel cylinder ensuring that the rubber boots are
(b) Remove the bolts retaining the wheel cylin- securely located in the cylinder. If necessary, use a
der to the backing plate and withdraw the wheel clamp to hold the pistons in the cylinder.
cylinder from the vehicle. (c) Position the wheel cylinder in the backing
(c) Remove the rubber boots, pistons and spring plate and install the brake pipe to the cylinder. Do not
from the wheel cylinder bore. Remove the seals from fully tighten the pipe at this stage.
the pistons. Discard the rubber boots and seals. (d) Install the wheel cylinder retaining bolts and
(d) Remove the rubber boot and bleeder valve tighten the retaining bolts and brake pipe securely.
from the wheel cylinder. Install and tighten the bleeder valve. Install the
valve
TO CLEAN AND INSPECT boot.
(1) Thoroughly clean all the brake components,
except the brake shoes in methylated spirits.
(2) Inspect the brake shoe linings. If the thick-
ness of the lining on one or more of the shoes is less
than 1.5 mm thick or contaminated with fluid or
grease, the brake shoes must be renewed as a set.
(3) Inspect the wheel cylinder bore and piston
for pitting, wear or damage. Renew the wheel cylinder
assembly if any damage is evident.
(4) Check the brake drums for cracks, scoring or
out of round. Renew or machine the brake drums as
necessary.
NOTE: If changing the brake fluid, continue to be made. Always use new brake fluid for
bleeding the system until clean new fluid topping up the reservoir.
flows from the bleeder hose. (6) Carry out the operation on the right front,
Do not allow the fluid level in the reser- right rear, right rear and left front brake in that order.
voir to fall below the one third full level at (7) Replenish the reservoir with the specified
any time during the operation or air will brake fluid to the indicated level and install the
enter the system and a fresh start will have reservoir cap.
190
ELECTRICAL SYSTEM
CAUTION: To prevent severe electrical shock extreme care must be taken when
working on or near the electronic ignition system as dangerous high tension voltages
are produced in both the primary and secondary circuits. See the text for
precautionary notes.
transaxle models, check for a faulty or incorrectly 1. Faulty lamp switch: Check and if necessary
adjusted neutral safety switch. renew the lamp switch.
1. Discharged battery: Check for a fault or short 2. Faulty fuse or fuse connection: Repair the
circuit in the system. fuse connection or renew the fuse.
2. Battery fully charged but will not crank 3. Lamp relay faulty: Check and renew as
engine. Check for a locked drive and ring gear, necessary.
internal starter fault or seized engine. NOTE: Switch on the lamps concerned and
3. Fusible link blown: Check and repair the using a test lamp, check that the lamp
cause and renew as necessary. circuits are operating. This is best done by
NOTE: Rotate the engine by hand to ensure starting at the lamp wiring connector or
that the starter drive is not locked with the bulb holder and working back to the power
flywheel ring gear and that the engine is not source.
seized. Ensure that the ignition key is
turned off before rotating the engine. LAMP OR LAMPS INCORRECTLY
ILLUMINATED
3. LIGHTING SYSTEM TROUBLE SHOOTING 1. Lamp or lamps incorrectly earthed: Check
the lamp earth for looseness or clean the contact,
LAMP OR LAMPS FAIL TO LIGHT either at the lamp body or wire.
2. Incorrect bulbs installed: Check the bulb
1. Faulty bulb(s): Check and renew the faulty wattage and voltage and renew with the correct type if
bulb(s). necessary.
2. Open circuit in the wiring or connections: 3. Dirty or damaged lamp reflector: Clean or
Check the lamp circuits and rectify as necessary. renew the lamp reflector.
4. Faulty bulb: Check with a known serviceable
bulb and renew if necessary.
5. Dirty lamp lens: Clean or renew the lamp
lens.
6. High resistance or faulty connections be-
tween the alternator and battery: Check the circuit
and rectify the condition.
7. Poor earth connection between the battery
and the engine or alternator: Check the battery earth
lead and the strap between the engine and the body.
8. Voltage regulator faulty: Check and renew
the voltage regulator.
NOTE: The most common cause for this
condition is dirty terminals on the earth
leads. Check all earth leads at their earthing
Checking the rear combination lamp circuit using a test points.
lamp.
4. TURN SIGNAL LAMP TROUBLE SHOOTING
TURN SIGNAL LAMP DOES NOT LIGHT AND
NO AUDIBLE NOISE FROM FLASHER UNIT
( 1 ) Fuse blown: Rectify the fault and renew the
fuse.
(2) The Flasher unit is faulty: Renew the unit
(3) Turn signal switch faulty: Renew the switch
(4) Fault in the wiring circuit: Check and repair
the fault.
TURN SIGNAL WARNING LAMP DOES NOT
FLASH BUT AUDIBLE CLICKING FROM
FLASHER UNIT
(1) Warning lamp bulb blown: Check and renew
the bulb.
Checking the headlamp circuit using a test lamp.
Electrical System 193
TO TEST BULBS
Remove the bulb from the bulb holder.
Connect a jumper lead between the positive
terminal of a battery and the base of the bulb.
Connect another jumper lead between the
negative battery terminal and the contact on the base
of the bulb. The bulb should illuminate.
If the bulb has two filaments, connect the jumper
lead to the second contact on the base of the bulb. The
second filament should illuminate.
If the bulb fails to illuminate, it should be
renewed with a bulb of the correct voltage and
wattage.
TO TEST CIRCUITS
Turn the circuit switch On.
Using a test lamp, check for power at one of
the circuit connections. A fuse is a good starting point.
If power is available, reconnect the connector and
continue checking towards the motor or bulb end of
the circuit.
If power is not available, continue checking
Schematic of LED test lamp. Ensure that the connec- towards the battery or switch end of the circuit.
tions to the K (cathode) lead and A (anode) lead of the
LED are as illustrated.
6. BATTERY
lead of the LED. The K lead is the shorter of the two
leads and is adjacent to the flat on the LED. Special Equipment Required:
Solder the 560 ohm resister to the A (anode) To Test — Hydrometer
lead of the LED. To Charge — Battery charger
Solder a short length of wire to the other lead
of the resistor and to the probe. TO REMOVE AND INSTAL
Drill a hole in the side of the case to accept
the wire attached to the K lead of the LED. (1) Disconnect the negative and positive battery
Mount the probe in the case. If using a pen terminals.
case, push the probe through the lower end of the pen
after removing the refill.
Push the lead attached to the K lead of the
LED through the hole made in the side of the case and
solder the alligator clip to the lead.
Mount the LED to the case. If using a pen
case, the LED may be mounted in the plug at the top
of the pen after drilling the plug to accept the LED.
Suitably attach the probe to the case using
adhesive or tape.
TO TEST SWITCHES
Disconnect the wires from the switch.
Using a test lamp, test each wire to locate the
power wire. It may be necessary to turn the ignition
On as the switch may be wired through the ignition
circuit.
Disconnect the test lamp and connect a Installed view of the battery.
Electrical System 195
(2) Remove the battery holding clamp and lift distilled water as necessary. The correct level is just
the battery from the vehicle. above the top of the plates. Do not overfill the battery.
Installation is a reversal of the removal procedure Do not transfer electrolyte from one cell to another.
with attention to the following points: (5) If the battery electrolyte requires frequent
Ensure that the terminals and posts are replenishing, check the battery case for cracks. If the
clean. case is damaged, renew the battery.
When connecting the leads to the battery, Check for overcharging by measuring the output
ensure that the polarity is correct. Connect the of the alternator as described later in this section.
positive lead first. Apply petroleum jelly to the battery termi-
Do not over tighten the terminal clamp nals to prevent corrosion.
nuts. If the electrolyte has overflowed and contam-
Apply petroleum jelly to the battery termi- inated the battery carrier and surrounding body
nals to prevent corrosion. panels, proceed as follows:
With the battery removed from the vehicle,
MAINTENANCE sprinkle bicarbonate of soda over the contaminated
Battery maintenance should be performed at the areas.
scheduled services. Pour hot water over the bicarbonate of soda.
NOTE: Keep naked flames away from the The bicarbonate of soda will react with the water and
battery as the battery gases are highly begin to foam.
explosive. When the bicarbonate of soda has stopped
foaming, rinse the area with clean water and allow to
(1) Keep the battery and the surrounding area dry.
clean and dry. In particular, ensure that the top of the Remove any blistered paint from the con-
battery is free from dirt and moisture to prevent a laminated areas.
voltage drop between the terminals. Paint the contaminated areas with a corro-
If necessary, clean the battery case as follows: sion inhibiting paint.
Remove the battery from the vehicle as
previously described. TO TEST AND CHARGE
Pour hot water over the battery being careful (1) Using a hydrometer, test the specific gravity
not to allow any water to enter the battery through the of the battery electrolyte. Refer to the following chart
filler cap vent holes. which shows charge conditions for various specific
Wipe the battery case clean. gravity readings.
Clean the battery terminals and posts using a
battery post cleaner, wire brush or emery cloth. 1.110-1.130............................... Fully discharged
Remove all dirt and corrosion. 1.140-1.160..............................Nearly discharged
Remove the filler caps and check that the 1.170-1.190...........................Approximately one
vent holes are clear. quarter charged
Check the electrolyte level and replenish with 1.200-1.220..................................... Half charged
1.230-1.250......................... Approximately three
quarters charged
1.250-1.280..................................... Fully charged
These readings are for electrolyte at a temperature
of 20 deg C. For every 10 deg above 20 deg C, add
0.007. For every 10 deg below 20 deg C, subtract
0.007.
NOTE: An accurate specific gravity reading
cannot be obtained if distilled water has
recently been added to the electrolyte. If the
electrolyte level is below the battery plates,
replenish with distilled water and charge the
battery before testing the specific gravity.
(2) If a low state of charge is indicated, or if the
specific gravity readings vary more than 0.030 be-
tween cells, the battery should be 'charged, using a
battery charger, with attention to the following points:
(a) Disconnect the negative and positive battery
Cleaning the battery terminals using a battery post terminals.
cleaner.
196 Electrical System
Switch on all lamps and allow them to NOTE: Refer to the Cooling and Heating
illuminate for approximately five minutes to reduce Systems section when refilling the radiator
the charge of the battery and to apply a load to the coolant to its correct level, failure to do so
circuit. could result in severe damage to engine
Start the engine and gradually increase the components.
speed to approximately 2 500 rpm. The reading on
the ammeter should be approximately 75% of the Remove the retaining bolts securing the
rated output of the alternator. See Specifications. thermostat housing, disconnect the hose from the
Switch off all the lamps and run the engine at radiator and remove the thermostat housing and
1 500-2 000 rpm until the indicated charge is below
10 amps. The voltmeter should now read in excess of radiator hose from the vehicle.
13.6 volts. Using a socket and extension bar, remove the
bolt securing the alternator to the drive belt tensioning
NOTE: Should the alternator fail to reach bar located under the alternator.
the specific output, the unit will have to be On vehicles not equipped with air condition-
removed and overhauled or a replacement ing, remove the front splash guard from under the
unit installed. front of the vehicle and remove the bolt securing the
Should the voltage reading be above or alternator to the drive belt tensioning bar.
below Specifications, the regulator will have Loosen the upper mounting bolts, slacken
to be renewed. the alternator drive belt and remove it from the
alternator pulley.
TO REMOVE AND INSTAL While supporting the alternator, remove the
upper mounting bolts and remove the alternator from
Disconnect the negative battery terminal. the vehicle.
On 1.8 liter engines, remove the bolt secur- Installation is a reversal of the removal procedure
ing the air cleaner intake duct and remove the air with attention to the following points:
cleaner intake duct. Do not over tension the drive belt. Refer
Drain the radiator by releasing the radiator to
drain plug, located at the bottom of the radiator and the Engine Tune-up section for the correct belt
allow the coolant level to fall below the thermostat adjusting procedure.
housing level. Ensure that the wiring and connectors are
securely located on the alternator.
(3) Replenish the coolant in the radiator. Refer (12) Working inside the slip ring end bracket,
to the Cooling and Heating Systems section for the remove the screws securing the diode pack to the
correct procedure. bracket and withdraw the stator and diode pack as an
assembly. Remove the insulating spacer and washer
TO DISMANTLE from the (B +) terminal.
Bosch Alternator
NOTE: The diode pack is supplied as an
Remove the alternator from the vehicle as assembly and in the event of a component
previously described. 'failure, must be renewed as a complete unit.
Scribe a mark across the drive end bracket,
stator and slip ring end bracket to facilitate correct Mark all wiring connections prior to removal
alignment during assembly. to aid assembly.
Remove the screws and washers securing the Where necessary, unsolder the stator leads
regulator and brush holder assembly. Withdraw the from the connector terminals to separate the diode
regulator and brush holder assembly from the alter- pack.
nator.
Remove the long screws securing the drive NOTE: When soldering or unsoldering the
end bracket to the slip ring end bracket and withdraw stator leads from the diodes, grip the leads
the drive end bracket, rotor and pulley assembly. with a pair of long nosed pliers. This will
safeguard the diodes by transferring any
NOTE: Ensure that the wave washer behind excess heat to the jaws of the pliers.
the rotor shaft rear bearing in the slip ring
end bracket is not mislaid.
Hitachi Alternator
Holding the rotor in a soft jawed vice,
remove the split drive pulley retaining nut, washer Remove the alternator from the vehicle as
and spacer from the rotor shaft. previously described.
Remove the split drive pulley, spacer, plate Scribe a mark across the drive end bracket,
washer and fan from the rotor shaft. stator and slip ring end bracket to facilitate correct
Using a suitable press and press plates, alignment during assembly.
support the drive end bracket with the pulley end of Remove the through bolts retaining the drive
the rotor shaft uppermost and carefully press the rotor end bracket to the slip ring end bracket.
shaft from the spacer, bearing and the drive end Apply a heated 200 watt soldering iron to the
bracket. slip ring end bracket at the bearing mounting boss for
Remove the spacer and the bearing retainer 3-4 minutes to heat the bracket and allow the removal
plate screws from the drive end bracket. of the slip ring end bearing.
Remove the bearing retainer plate and the Carefully prise the slip ring end bracket and
bearing from the drive end bracket. stator assembly from the drive end bracket and rotor
If necessary, using a bearing puller, remove assembly using suitable levers. Do not insert the levers
the rear bearing from the rotor shaft. too far or damage to the stator will occur.
Remove the nut, spring washer and output Hold the rotor and drive end bracket assem-
terminal components from the {B + ) terminal on the bly in a soft jawed vice and remove the nut retaining
outside of the slip ring end bracket. the drive pulley to the rotor.
Remove the washer, pulley and spacer
washer from the rotor shaft.
Using a soft faced hammer, drive the rotor
shaft assembly from the drive end bracket and remove
the inner spacer washer from the rotor shaft.
Remove the bearing retainer plate screws
and remove the plate. Using a suitable drift, drive the
bearing from the bracket.
Remove the retaining nut and insulator
washer from the alternator terminal.
Remove the slip ring end bracket retaining
nuts and separate the diode pack, stator and regulator
assembly.
If necessary, file the ends of the brush
assembly retaining rivets, carefully unsolder the ter-
minal plate and remove the brush assembly and
terminal plate from the diode pack.
View of the Bosch alternator stator assembly and the If necessary, remove the fan guide retaining
slip ring end bracket.
Electrical System 199
TO ASSEMBLE
Bosch Alternator
Assembly is a reversal of the dismantling proce-
dure with attention to the following points:
Using a hot soldering iron and a pair of long
nosed pliers as a heat sink, solder the stator leads to
their respective terminals on the diode pack.
Install the insulating washer and spacer to the
(B +) terminal post and position the diode pack and
stator assembly onto the slip ring end bracket. Install
the diode pack retaining screws and tighten securely.
Working on the exterior of the slip ring end
bracket, install the output terminal components to
the
(B + ) terminal and secure the retaining nut.
Position the bearing retainer, bearing and
Using an ohmmeter to test for bridging or internal
spacer on the rotor shaft.
shorting of the rotor fields.
Using a suitable press and press plates,
internally, while a high reading indicates an open support the rotor shaft on the front face of the spacer
circuit or high resistance in the windings. In both and carefully press the rotor shaft fully into the
cases a new rotor assembly will have to be installed. bearing and spacer.
Position the rotor shaft assembly into the
Stator Windings rear of the drive end bracket and install and tighten the
bearing retainer plate screws.
The stator test is carried out using a test lamp. Install the fan, plate, spacer and split
The stator leads must be detached from the drive
diode pack. pulley to the rotor shaft and secure them with the
Connect a jumper lead from the negative retaining washer and nut.
terminal of a charged 12 volt battery to the stator If necessary, using a suitable press and press
winding frame. Connect one end of a test lamp to the plates, support the rotor shaft rear bearing and
battery positive terminal, the other end of the test carefully press the rotor shaft fully into the bearing.
lamp to the stator lead, one at a time. NOTE: Ensure that pressure is applied only
Should the test lamp illuminate, however to the inner race of the bearing.
dimly, a short circuit is indicated and the stator
assembly must be renewed. Ensure that the rotor shaft bearing wave
washer is located in the slip ring end bracket and
Diodes insert the rotor in the stator and slip ring end bracket
assembly.
On some models the diodes may be tested after Align the marks made on dismantling and
disconnection. Testing can be done by using a 12 volt install and tighten the long securing screws.
battery and a 1.5 watt bulb in series with a jumper Position the regulator and brush holder as-
lead.
Connect a jumper lead from the negative sembly to the slip ring end bracket and install
terminal of a charged battery to the carrier/bracket and
holding the diode to be tested. tighten the retaining screws.
Connect one end of a test lamp to the battery Install the alternator to the vehicle and
positive terminal and the other end of the lamp to the test
diode lead. Note whether the lamp is illuminated and the operation as previously described.
then reverse the connections on the battery.
If the lamp was illuminated in both direc- Hitachi Alternator
tions or was not illuminated at all, the diode is faulty If necessary, position the new brush termi-
and the diode pack/heat sink must be renewed. nals in the brush assembly and install the
brush
Brush Springs and Brushes assembly and terminal plate to the diode pack.
Check the brush springs for overheating and Carefully solder the terminal plate to the diode pack
distortion, check for binding in the brush holder. and secure the brush assembly by installing and
Check the brush length and renew as neces- staking new rivets.
sary. Refer to Specifications for the correct dimen- If necessary, solder the diode pack and
sions. regulator to the stator and install the fan guide
and
retaining nuts. Tighten the retaining nuts securely.
NOTE: When soldering or unsoldering the
stator leads or bridges from the diodes or
regulator, grip the leads with a pair of long
Electrical System 201
nosed pliers. This will safeguard the diodes A solenoid switch is attached to the starter drive
by transferring any excess heat to the jaws of end bracket. The solenoid plunger is connected to
the pliers. the overrunning clutch and drive pinion assembly
Using a suitable drift, install the bearing into through a lever and pivot arrangement.
the drive end bracket, install the retainer plate and When the solenoid windings are energized, the
screws. Tighten the screws securely. plunger acting on the lever and pivot engages the drive
Using a suitable press and press plates, install pinion with the flywheel ring gear and at the same
the bearing to the slip ring end of the rotor shaft. time closes the switch supplying power from the
Ensure that pressure is exerted only on the inner race positive lead of the battery to the starter motor field
and that the stop ring groove is nearest to the slip coils and armature to operate the motor.
rings. As the engine fires, the over-running clutch of the
Ensure that the rotor shaft rear bearing stop drive pinion assembly prevents high speed rotation of.
ring is positioned so that the protruding part of the and possible damage to, the starter armature if the
ring is located in the deepest part of the groove. solenoid windings are not immediately de-energized
Install the stator, diode pack and by releasing the ignition key.
regulator The starter solenoid switch windings are energized
assembly to the slip ring end bracket. Install the by the ignition switch.
retaining nuts and washers and tighten securely.
Install the nut and insulator to the terminal TO TEST ON VEHICLE
and tighten securely.
Using a piece of wire, hold the brushes in a Should the starter motor fail to operate when the
retracted position. ignition switch is turned to the Start position, check
Hold the drive end bracket in a soft jawed the following points:
vice and install the rotor shaft assembly to the drive Check the battery condition and state of
end bracket. charge. Refer to the Battery heading for the correct
Install the pulley, retaining nut and washer to procedure.
the rotor shaft and tighten the retaining nut to the Clean the battery terminals, taking particular
specified torque. care to remove the scale from the positive ( + )
Apply a heated 200 watt soldering iron to the terminal post and terminal.
slip ring end bracket at the bearing mounting boss for Check the earth connection for tightness and
3-4 minutes to heat the bracket and allow the cleanliness.
installation of the rotor shaft rear bearing. Switch on the headlamps and turn the igni-
Aligning the marks made on dismantling and tion switch to Start. If the lamps dim but the starter
ensuring that the rotor shaft rear bearing retaining motor does not operate, it could indicate that a short
ring protrusion is located in the deepest part of its circuit has developed in the starting system.
groove, install the rotor/stator assembly to the slip ring Check that the engine is not seized or that the
end bracket. starter motor drive pinion and ring gear are not
Remove the brush retracting wire from the locked as these conditions would -give the same
alternator, ensure that the alternator component indications as above.
marks are aligned, install the retaining through bolts (5) If the lamps do not dim and the starter
and tighten them securely. motor does not operate, this would indicate an open
Check the alternator rotor for smooth oper- circuit such as a broken or disconnected wire or a
ation and install the alternator to the vehicle switch not operating.
as If the vehicle is equipped with an automatic
previously described. transaxle, turn the ignition switch to Start and move
Check the alternator operation on the vehicle the selector lever through all the gear selection range.
If the starter motor operates in any position other
as previously described. than N or P, the neutral safety switch is faulty.
(6) Check all the external wiring to ensure that
8. STARTER MOTOR the fault is not external. If the external circuit proves
satisfactory, indicating that the problem is in the
Special Equipment Required: starter motor, the unit will have to be removed and
To Renew Brushes — Soldering iron tested.
To Renew Armature Bearings — Bearing puller
TO REMOVE AND INSTAL
DESCRIPTION
Disconnect the negative battery terminal.
Two types of starter motors are installed to the Disconnect the wiring from the starter motor
range of vehicles covered by this manual, either solenoid.
Hitachi or Bosch. Remove the starter motor mounting bolts,
The starter motor is the induced pole type with
four brushes and four pole shoes with field coils.
202 Electrical System
PLUNGER
O RING
BRUSH HOLDER
Check the field coil insulation using an assembly and the armature. Lubricate the armature
ohmmeter. Connect one test probe to the solenoid bearings with high temperature grease.
cable terminal and the other test probe to the body of The sealed bearings on the clutch assembly are
the yoke. If continuity exists, renew the field coils. lubricated during manufacture and further lubrication
Check that the commutator is free from is unnecessary.
pitting and burning. Clean the commutator with a Apply high temperature grease to the yoke
petrol moistened cloth and polish with a strip of fine end cover bearing recess, the drive end bracket and
glass paper. pinion housing bearing recesses, the clutch assembly
A badly worn commutator may be repaired by reduction gear teeth, the armature gear teeth, the
mounting in a lathe and taking a light cut using a very pinion helical splines, the solenoid plunger and the
sharp tool with the lathe rotating at high speed. After spring and lever.
machining, undercut the insulation between the seg- Install the pinion to the clutch assembly and
ments to Specifications. Do not machine the commu- install the spring and collar to the pinion.
tator to below 29 mm diameter. Check the armature Hold the collar down and install the snap ring
gear teeth for wear and damage. to the end of the pinion.
Check the armature for short circuit using an Position the collar over the snap ring. If
ohmmeter. Place one of the test probes on the necessary, squeeze the snap ring into the groove using
armature shaft or core and move the other test probe multigrip pliers to enable the collar to be clipped over
around the periphery of the commutator. If continuity the snap ring.
exists at any point, the armature is faulty and should Install the pinion and clutch assembly to the
be renewed. drive end bracket.
Check the pinion for wear and damage. The Install the pinion housing to the drive end
pinion should move smoothly along the clutch assem- bracket. Install and tighten the retaining screws
bly helical splines. Check the spring, collar and snap se-
ring for serviceability. curely. Check that the pinion rotates freely.
Check that the clutch assembly locks in one Assemble the lever and spring to the solenoid
direction and rotates smoothly in the opposite direc- in the position noted on dismantling.
tion. Check for wear and damage to the reduction gear Install the solenoid assembly and rubber seal
teeth on the outside of the clutch assembly. to the drive end bracket.
Check that continuity exists between the Install and tighten the solenoid retaining
solenoid spade terminal and the solenoid body and bolts securely.
between the solenoid spade terminal and the solenoid Connect 12 volts between the solenoid spade
field coil terminal. Renew the solenoid if continuity terminal and the solenoid field coil terminal and
does not exist. measure the distance that the end of the pinion
Renew all the components found to be protrudes from the pinion housing.
unserviceable in the above checks. Pull the pinion by hand until it contacts the stop
and measure the pinion end protrusion.
To Assemble If necessary, add or subtract shims between the
solenoid mounting face and the drive end bracket
Assembly is a reversal of the dismantling proce- until the difference between the above measurements
dure with attention to the following points: is 0.3-1.5 mm.
(1) If removed, install new bearings to the clutch Install the armature to the yoke.
Install the brush holder to the yoke. Install
the
204 Electrical System
brushes to the brush holder and position the springs Remove the rubber seal from the drive end
against the ends of the brushes. bracket.
Install the O ring to the yoke taking care Remove the cover plate from the planetary
that gear set and remove the gear set, drive assembly and
the O ring is not twisted. engaging lever as an assembly.
Install the yoke, armature and brush Remove the armature end cover and com-
holder mutator end bracket from the yoke.
assembly to the drive end bracket, aligning the marks Remove the screws retaining the armature
made on dismantling. end cover to the commutator end cover and remove
Install the end cover to the yoke. Install the armature end cover, C clip and shims from the
and armature shaft. Remove the commutator end bracket
tighten the retaining bolts securely. from the armature.
Connect the cable to the solenoid field coil Carefully remove the brush holder from the
terminal and tighten the terminal nut securely. armature.
Install the starter motor to the vehicle Support the gear set and drive assembly in a
as vertical position with the drive assembly uppermost.
previously described. Using a suitable drift, tap the stop collar
towards the drive assembly and remove the snap ring
BOSCH STARTER MOTOR from the drive shaft.
To Dismantle Remove any burrs from the drive shaft and
Disconnect the brush connector strap from withdraw the drive assembly and stop ring from the
the lower terminal on the solenoid switch. drive shaft.
Remove the screws retaining the solenoid to Clean all parts thoroughly but do not im-
the drive end bracket and remove the solenoid from merse the armature, solenoid or drive assembly in
the drive end bracket. cleaning solvent.
Loosen, but do not remove the screws retain-
ing the armature end cover to the commutator end To Check and Inspect
bracket. (1) With the starter motor dismantled, check the
Remove the through bolts retaining the drive brush holder insulation using an ohmmeter.
end bracket to the commutator end bracket. Connect one test lead to the brush holder positive
Remove the yoke, armature and commutator
end bracket from the drive end bracket as an assem-
bly. Hold the rubber seal in place in the drive end
bracket to keep the engaging lever in position.
BRACKET
Install the armature and yoke to the drive end Disconnect the ignition switch wiring at the
bracket rotating the drive to align the reduction gears. switch.
Do not use force. Remove the retaining screw and withdraw
Install the retaining through bolts to the the ignition switch from the lock assembly.
commutator end bracket and lighten the through bolts Installation is a reversal of the removal procedure.
and armature end cover retaining screws securely.
Install the solenoid to the drive end bracket, COMBINATION SWITCH
install the retaining screws and tighten them securely.
Install the brush connector strap and The combination switch is mounted at the top of
install the steering column and incorporates two switches.
the retaining nut and washer and tighten securely. The parking lamp, headlamp, headlamp flasher, head-
lamp dipper and turn signal lamps are operated by a
lever on the right hand side. A lever on the left hand
9. IGNITION SYSTEM side operates the windscreen washer and wiper switch.
These switches can be renewed without removing
The testing and repair procedures for the ignition the combination switch.
system are fully covered in the Fuel and Engine
Management section. To Remove and Install Switches
Remove the retaining screws from the steer-
10. STEERING WHEEL ing column cover.
Unclip and separate the upper and lower
The removal and installation procedures for the steering column covers and remove the upper cover.
steering wheel and horn pad are fully covered in the
Steering section.
12. INSTRUMENT CLUSTER (d) Withdraw both instruments from the front of
the instrument cluster being careful as these instru-
TO REMOVE AND INSTAL ments are held by protruding pin terminals.
Disconnect the negative battery terminal. NOTE: Do not touch the faces of the instru-
Remove the retaining screws from the instru- ment dials as they mark easily.
ment cluster surround. (e) On models equipped with a tachometer,
Carefully withdraw the instrument cluster remove the retaining nuts and remove the tempera-
surround from the instrument panel sufficiently to ture and/or the fuel gauge from the cluster assembly.
enable the wiring to be disconnected. Remove the Installation is a reversal of the removal procedure
surround from the vehicle. ensuring that all electrical connectors are correctly
.
BULB HOLDERS
installed.
13. BLOWER FAN
BULB HOLDERS
TO REMOVE AND INSTAL
FLEXIBLE PRINTED
CIRCUIT Disconnect the negative battery terminal.
Rear view of the instrument cluster removed from the Remove the release hole covers on each side
vehicle. of the radio/cassette.
(4) Remove the instrument cluster assembly
retaining screws and gently ease the assembly from the
instrument panel sufficiently to enable the wiring to be
disconnected.
If necessary, remove the instruments as follows:
Carefully depress the retaining clips on the
front lens and remove the front lens.
On models equipped with a tachometer, slide
the plastic rib from between the speedometer and the
tachometer.
Remove the screws retaining the speedome-
ter and the tachometer or fuel/temperature gauges
from the rear of the instrument cluster.
CLUSTER ASSEMBLY
When using an aiming board, position the To Renew High Beam Bulb (Pulsar) or
vehicle five meters from and square to the aiming High/Low Beam Bulb (Astra)
board. Gently rock the vehicle and allow the suspen- Disconnect the wiring connector and re-
sion to stabilize. move the dust cover from the rear of the headlamp.
Mark a reference line on the board to Release the retaining clip and remove the
correspond with the horizontal centre line of the bulb from the bulb holder.
headlamp low beam bulbs. Install the new bulb to the headlamp ensur-
Mark two reference lines on the board to ing that the metal plate is correctly located in the
correspond with the vertical centre lines of
the bulb holder.
headlamp low beam bulbs.
Switch on the headlamps and select low NOTE: Care must be taken not to handle
beam. the glass portion of the bulb as this will
Adjust the headlamps by turning the adjust- shorten the life of the bulb.
ing screws located at the rear of the headlamp Accidental fingerprints can be re-
assemblies. moved by applying methylated spirits to
Adjust the headlamps to comply with local the bulb and drying with clean tissue or
regulations. As a guide, adjust the lamps so that the cloth.
low beam pattern strikes the aiming board with the
horizontal cut off point 50 mm below the headlamp (4) Secure the retaining clip, install the cover to
bulb horizontal centre line and the point where the the headlamp and connect the wiring to the end of the
beam raises from the horizontal is on the headlamp bulb.
low beam bulb vertical centre line.
FRONT COMBINATION LAMP (PULSAR)
To Renew Low Beam Bulb (Pulsar) OR TURN SIGNAL LAMP (ASTRA)
Remove the dust cover from the rear of the To Renew Bulb
headlamp assembly. (1) Remove the retaining screws from the front
Disconnect the wiring from the end of the combination lamp and remove the lens.
bulb.
Remove the cover from the rear of the
headlamp housing.
Release the retaining clip from the bulb
holder and withdraw the bulb from the headlamp.
Installation is a reversal of the removal procedure
ensuring that the new bulb is correctly located in the
bulb holder.
NOTE: Care must be taken not to handle
the glass portion of the bulb as this will
shorten the life of the bulb. Accidental
fingerprints can be removed by applying
methylated spirits to the bulb and drying
with clean tissue or cloth.
Renewing the high mounted stop lamp bulb. Removing the wiper blade.
Remove the bulb holder from the lamp by arm and slide the wiper blade along the arm towards
twisting it anti-clockwise and removing it from the the pivot to allow the blade to be maneuvered from
lamp body. the arm.
Push the bulb inwards, turn it anti-clockwise Installation is a reversal of the removal procedure
and remove it from the holder. ensuring that the blade snaps into place as it is
Installation is a reversal of the removal procedure. installed to the wiper arm.
WIPER LINKAGE
To Remove and Install
Remove both windscreen wiper arms as
previously described.
Carefully prise the wiper arm drive linkage
from the ball stud on the wiper motor driving crank.
Remove the retaining nuts and metal spacers
from the wiper arm drive spindle housings.
Maneuver both drive spindle housings into
the plenum chamber taking care not to damage the
paintwork. Ensure that the water seals on the spindle
housings arc not lost during the removal procedure.
Remove the assembly from the vehicle.
Installation is a reversal of the removal procedure.
Removing the rear wiper arm.
WINDSCREEN WIPER MOTOR
To Remove and Install
(1) Disconnect the negative battery terminal.
Installed view of the windscreen wiper motor. Installed view of the rear wiper motor.
Electrical System 215
Ensure that the wiper motor is in the Park Remove the cover from the lower right hand
position before installing the wiper arm. If in doubt, corner of the dashboard and using the information
turn the wiper switch to the Off position and turn the marked on the fuse box, locate the fuse protecting the
ignition switch to the On position until the wiper circuit at fault.
motor stops. Pull the fuse out of the fuse box and inspect
Install the wiper arm to the pivot so that the it for serviceability.
wiper blade is horizontal to the lower edge of the edge Should the fuse appear to be in a serviceable
of the rear window when in the Park position. condition, test its continuity with an ohmmeter or test
lamp.
17. FUSES, FUSIBLE LINKS AND RELAYS Should the fuse be faulty or burnt out,
install
TO CHECK AND RENEW FUSE a new fuse of the same amperage.
If the circuit is still inoperative or the fuse
NOTE: If a fuse is found to be faulty or burns out again, test the circuit as previously de-
burnt out, use a replacement fuse of the scribed in this section or refer the problem to an
specified amperage only. The specified amp- automotive electrician.
erage is marked on the fuse.
The use of a higher amperage fuse than TO CHECK AND RENEW FUSIBLE LINK
that specified could cause damage to the
vehicle wiring harness. NOTE: If a fusible link is found to be faulty
The fuses are mounted in a fuse box or burnt out, use a genuine replacement
located in the lower right hand corner of the fusible link of the specified amperage only.
dashboard. The use of a higher amperage fusible link
than that specified could cause damage to
the vehicle wiring harness.
A new fusible link should never be in-
stalled until the fault which caused the
original link to fail has been repaired.
The fusible links installed to protect the
vehicles wiring system are located adjacent
to the washer bottle on the right hand inner
mudguard.
Disconnect the negative battery terminal
Check the fusible link visually for service-
ability.
Should the fusible link appear to be in a
serviceable condition, test its continuity using
an
ohmmeter or a test lamp.
If the fusible link proves to be faulty, install
View of the fuse box.
a
new fusible link and have an assistant temporarily
connect the battery while the circuit is checked for
operation.
RELAY LOCATIONS
The various relays employed in the vehicle elec-
trical system are located behind the fusible links
adjacent to the washer bottle in the engine compart-
ment, on the engine compartment bulkhead, under
the windscreen wiper motor and in the fuse box at the
lower right hand side of the dashboard.
The engine compartment relays power the radia- Installed view of the fuse box relays.
tor fan, horn, condenser fan, bulb check, automatic
transaxle neutral safety switch, air conditioner and The fuse box relays power the fuel pump, ignition,
condenser motor. some accessories and the electronic control module.
18. TRAILER WIRING
There are several brands of trailer wiring connec-
tors available with a variety of pin configurations. The
most common is the seven pin type which provides
for two auxiliary circuits, usually used for reverse
lamps and electric trailer brakes.
Connect a jumper lead from the negative terminal jumper lead, noting the color of the wire
terminal of a 12 volt battery to the earth wire. and the lamp circuit operated.
Connect a jumper lead from the positive (3) After installation, connect the trailer plug to
terminal of a 12 volt battery and connect each of the the socket on the vehicle and check for correct lamp
trailer lamp wires in turn to the positive battery operation.
Vehicle and trailer wired to conform to Australian Standard AS2513. Sockets and plug shown are as viewed
from the terminal side of the component. Refer to the text for the correct terminal applications when using a
5 or 6 pin socket and plug.
COLOUR CODE
B - Black 1 To vehicle wiring 7. Trailer reverse lamp
G - Green
L - Blue harness 8. Trailer L H turn signal
N - Brown 2. 7 pin socket — Bosch. lamp
R - Red
Hella. Utilux 9. 6 pin socket - Utilux
W - Whlte
Y -Yellow 3 7 pin plug - Bosch, 10. 5 pin socket - Bosch
Hella, Utilux Hella
4. Trailer R H turn signal 11. 7 pin socket - Brylite
lamp 12. Trailer electric brakes
5. Trailer tail lamp
6. Trailer stop lamp
Electrical System 219
Wiring diagram (WDI) for the starting, charging and engine management systems.
Wiring diagram (WD2) for the instruments, hazard and turning signal systems.
Wiring diagram (WD3) for the fan switch, blower, air conditioning, rear demister and power
window circuits.
Wiring diagram (WD4) for the horn, audio, front wiper/washer and rear wiper/washer circuits.
Wiring diagram (WD5) for the mirrors, cigarette lighter and door lock circuits.
BODY
2. FRONT DOORS
Dismantled view of the front door lock components. Dimension A at the stepped adjuster holder should be
0.5-2.0 mm. Turn the stepped adjuster holder to give the correct free play.
EXTERIOR DOOR HANDLE Wind the door glass up fully and disconnect
To Remove and Install the operating link between the door lock and the lock
Remove the interior handles, the trim panel cylinder.
and the plastic sealing sheet as previously described. Using a suitable screwdriver, remove the
Remove the retaining nuts from inside the lock cylinder retaining clip and withdraw the lock
door panel. Withdraw the handle slightly while ensur- cylinder from the outer door panel.
ing that the link is sliding out of the lock assembly.
Maneuver the exterior handle from the vehicle. Installation is a reversal of the removal
Installation is a reversal of the removal procedure procedure.
with attention to the following points:
Ensure that the exterior handle and seal are LOCK STRIKER PLATE
in a serviceable condition and installed correctly to To Remove, Install and Adjust
prevent the entry of dust and water.
Ensure that the exterior handle operates Mark the position of the striker plate on the
correctly and has 0.5-2.0 mm free play at the stepped door pillar with a soft lead pencil to facilitate correct
adjuster holder. Adjust the stepped adjuster holder if replacement of the striker plate.
necessary. Remove the retaining screws from the striker
Check the operation of the door lock assem- plate to the door pillar and remove the striker plate.
bly before installing the plastic sealing sheet, the trim Inspect the striker plate for wear and renew as
panel and the interior handles as previously described. necessary.
Install the striker plate to the door pillar
LOCK CYLINDER according to the pencil marks made on removal.
To Remove and Install Close the door and observe the alignment
with the body panel or rear door. If necessary, loosen
(1) Remove the interior handles, the trim panel the striker plate retaining screws and move the striker
and the plastic sealing sheet as previously described. plate in or out to achieve a flush fit.
If the door lifts or drops when the lock
228 Body
3. REAR DOORS
INTERIOR HANDLES AND TRIM PANEL
To Remove and Install
On models with manual windows, carefully
prise out the armrest trim plugs and remove the
retaining screws. Withdraw the armrest from the
vehicle.
On models with power windows, proceed as
follows:
Carefully prise out the armrest trim plugs
and remove the retaining screws.
Hold the armrest away from the door trim
panel as much as possible and lever the window
switches out from the armrest, front end first.
Lift the switches and disconnect the wiring
connector.
Installed view of the front door lock striker plate. Remove the hidden screw, working through
the switch aperture. Withdraw the armrest from the
engages the striker plate, loosen the retaining screws vehicle.
and move the striker plate up or down to eliminate (3) Remove the screw retaining the remote con-
the lift or drop.
EXTERNAL MIRROR
To Remove and Install
On models with manual mirrors, remove the
screw retaining the adjuster arm handle and withdraw
the handle.
Carefully prise out the cover trim plate and
remove the retaining screws securing the mirror body SNIPPER BUTTON
to the door.
On models with power mirrors, disconnect REMOTE CONTROL
the mirror wiring connector.
Withdraw the external mirror and seal from
the door.
Rear door with the trim panel and plastic sealing sheet
Dismantled view of the power door mirror. removed.
Body 229
Dismantled view of the rear door lock components. Dimension A at the stepped adjuster holder should be
0.5—2.0 mm. Turn the stepped adjuster holder to give the correct free play.
Ensure that the snipper button pivot holder Install the striker plate to the door pillar
is turned back to lock the pivot in position. according to the pencil marks made on removal.
Ensure that the exterior handle operates Close the door and observe the alignment
correctly and has 0.5-2.0 mm free play at the stepped with the body panel. If necessary, loosen the striker
adjuster holder. Adjust the stepped adjuster holder if plate retainer screws and move the striker plate in or
necessary. out to achieve a flush fit between the door and the
Check the operation of the door lock assem- body panel.
bly before installing the plastic sealing sheet, the trim
panel and the interior handles as previously described.
LOCK STRIKER PLATE (5) If the door lifts or drops when the lock
To Remove, Install and Adjust engages the striker plate, loosen the screws and move
the striker plate up or down to eliminate the lift or
Mark the rear door pillar around the striker drop.
plate with a soft lead pencil to aid assembly.
Remove the retainer screws from the striker NOTE: After each adjustment tighten the
plate and remove the striker plate. Inspect the striker striker plate screws and check the adjust-
plate for wear or damage and renew as necessary. ment. Readjust as necessary.
Body 231
Installed view of the bonnet catch. View showing the right hand side tailgate components.
232 Body
leaving the ends of the string protruding from the Remove the striker plate retaining bolts and
tailgate. Untie the string. partially remove the striker plate.
Disconnect the remote tailgate release cable
NOTE: The string will be used to pull the from the striker plate and remove the striker plate
wiring through the tailgate on installation. from the vehicle.
If the wiring is pulled from the tailgate Inspect the striker plate for wear and renew
without the string attached, installation will it if necessary.
be very difficult. Installation is a reversal of the removal procedure
With the aid of an assistant supporting the with attention to the following points:
tailgate, prise out the ball joint stud snap locks from Install the striker plate ensuring that it is in
each upper strut ball joint using a small screwdriver. the position marked on dismantling and that the
Remove the bolts retaining the hinges to the remote tailgate release cable is connected. Tighten the
tailgate and carefully withdraw the tailgate from the retaining bolts.
vehicle. Close the tailgate ensuring that the striker
has actuated the locking mechanism.
To Install and Adjust Check the alignment of the tailgate in its
opening and adjust the locking action by moving the
With the aid of an assistant, install the striker plate in the required direction. Tighten the
tailgate in position on the hinges according to the retaining bolts securely.
marks made on removal and install the retaining bolts.
Install the tailgate support struts and retain LOCK AND LOCK CYLINDER
the ball joints with the snap locks. To Remove and Install
Pull the tailgate wiring through using the
piece of string. Connect the wiring and install Prise out the tailgate trim panel retaining
the clips and carefully maneuver the tailgate interior
tailgate trim panel. trim panel from the tailgate.
Close the tailgate and check the vertical and Disconnect the actuating rod from the lock
lateral alignment of the tailgate in relation to the cylinder assembly.
body. Disconnect the interior lamp switch wiring
If adjustment is required, loosen the tailgate connector.
hinge retaining bolts one hinge at a time and adjust
the tailgate as required.
If vertical adjustment is required, it will be
necessary to remove or install washers under the
tailgate hinges.
If required, adjust the striker plate using the
procedure that follows.
STRIKER PLATE
To Remove, Install and Adjust
Using a flat bladed screwdriver, prise out the
trim plugs and remove the trim plate from above the
striker.
Using a soft lead pencil, scribe a line around
the striker plate.
Installed view of the striker plate assembly. Hatchback Dismantled view of the Hatchback lock and lock cylin-
models. der.
Body 233
Remove the lock assembly retaining bolts If vertical adjustment is required, loosen the
and withdraw the lock assembly, insulator and link lid hinge retaining bolts and increase or decrease the
from the tailgate. number of washers under the bolts.
Using a suitable screwdriver, remove the If required, adjust the striker plate using the
lock cylinder retaining clip and withdraw the lock procedure that follows.
cylinder from the vehicle.
Installation is a reversal of the removal procedure STRIKER PLATE
with attention to the following points: To Remove, Install and Adjust
Ensure that the positioning of the lock is Fold back the trim material from inside the
correct in relation to the striker plate. luggage compartment.
Ensure that the interior lamp switch wiring Using a soft lead pencil, scribe a line around
connector is connected. the outside of each striker plate retaining bolt washer.
Remove the striker plate bolts and washers
6. LUGGAGE COMPARTMENT LID and the screw retaining the remote release cable
AND LOCK — SEDAN bracket.
LUGGAGE COMPARTMENT LID
To Remove
Raise the luggage compartment lid and place
protective covers over the surrounding paintwork.
Using a soft lead pencil, mark around the
luggage compartment lid hinges to aid assembly.
With the aid of an assistant supporting the
lid, remove the hinge retaining bolts and withdraw the
luggage compartment lid from the vehicle.
To Install and Adjust
With the aid of an assistant, install the
luggage compartment lid in position on the hinges
according to the marks made on removal. Install the
retaining bolts.
Close the lid and check the vertical and
lateral alignment of the lid in relation to the body. Installed view of the luggage compartment lid striker
If adjustment is necessary, loosen the lid with the trim material folded back.
hinge retaining bolts on one hinge at a time and adjust (4) Slide the striker assembly towards the right
the lid as required. hand side of the vehicle and disconnect the remote
release cable. Withdraw the striker plate from the
vehicle.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Install the remote release cable to the striker
plate and install the striker plate retaining bolts and
washers to the lines made on dismantling.
Tighten the retaining bolts to just over finger
tight.
Close the lid ensuring that the striker has
actuated the locking mechanism.
Check the alignment of the luggage compart-
ment lid in its opening and adjust the locking action
by moving the striker plate. Tighten the retaining
bolts securely.
When the striker plate is adjusted correctly
pull the remote release cable towards the right hand
side of the vehicle until the cable end has 0.5-1.5 mm
clearance and tighten the retaining screws. Check the
operation of the remote release cable and readjust if
Installed view of the luggage compartment lid hinge.
necessary.
234 Body
LOCK ASSEMBLY (2) When the clips have been released, pull the
To Remove and Install grille forward and remove it from the vehicle ensuring
that care is taken not to damage the grille.
(1) Remove the retaining bolts and withdraw the Installation is a reversal of the removal procedure
lock assembly from the luggage compartment lid. with attention to the following points:
Installation is a reversal of the removal procedure Remove the grille retaining clips from the
ensuring that the actuating arm on the lock is under radiator support panel and install them to the
the lock cylinder pivot. grille.
Renew any damaged clips.
LOCK CYLINDER Install the grille to the vehicle being careful to
align the grille clips before pushing the grille inwards.
Post July 1989 Pulsar Models
Fabricate a tool to engage the radiator grille
clips from the inside; an old spanner of suitable
dimensions can be ground down if necessary.
Using the above tool, turn the lower radiator
clips slightly to allow removal of the grille.
LOCK CYLINDER
To Remove and Install
Remove the bolt retaining the lock cylinder
pivot to the luggage compartment lid inner panel.
Using a suitable screwdriver, remove the
lock cylinder retaining clip from under the lock.
Withdraw the lock cylinder and pivot from
the vehicle.
Installation is a reversal of the removal procedure.
7. RADIATOR GRILLE Installed view of the radiator grille on post July 1989
models showing the retaining clip locations and the
TO REMOVE AND INSTAL special tool required to release the lower clips.
Astra Models and Pre July 1989 Pulsar Models Using a flat bladed screwdriver, turn the
(1) Using a flat bladed screwdriver, turn the upper grille clips slightly to allow removal of the grille.
grille clips slightly to allow removal of the grille. When all the clips have been released, pull
the grille forward and remove it from the vehicle
ensuring that care is taken not to damage the grille.
Installation is a reversal of the removal procedure
with attention to the following points:
Remove the grille clips from the radiator
support panel and install them to the grille. Renew any
damaged clips.
Install the grille to the vehicle being careful to
align the grille clips before pushing the grille inwards.
8. CENTRE CONSOLE
TO REMOVE AND INSTAL
Remove the carpet square from the rear part
of the console and remove the screws underneath.
Installed view of the radiator grille on pre July 1989 Prise out the trim piece below the handbrake
models showing the retaining clip locations.
Body 235
View of the dashboard removed from the vehicle. The arrows indicate the location of the retaining bolts.
236 Body
11. SEATS
FRONT SEAT
To Remove and Install
Adjust the seat to the most forward position.
Remove the mounting bolts from the rear of
the seat.
Adjust the seat to allow access to the mount-
ing bolts at the front of the seat.
Remove the mounting bolts and withdraw
Installed view of the front seat belt with the door pillar the seat from the vehicle.
trim removed showing the mounting points.
Body 237
first hose all dirt from the underbody and clean out
the drain holes in the doors and sill panels.
Hose the vehicle to remove as much grit as
possible and wash using a clean chamois or sponge,
ensuring that the chamois or sponge is free from dirt
or grit which could scratch the paint surface.
Avoid washing the vehicle in bright sunlight with
high temperature as this will give the paintwork a
streaky watermarked finish.
If necessary, wash the vehicle using a reputable
brand Wash and Wax liquid. The Wash and Wax
liquid will restore the paint luster and leave the
paintwork with a protective coating of wax.
After a period it may become necessary to polish
Installed view of the front seat mounting bolts.
the vehicle in order to remove built up foreign matter
and give the paintwork maximum protection from
Installation is a reversal of the removal procedure industrial fall-out and salt from sea air etc. Before
with attention to the following points: polishing the paintwork, always wash the surface to
Lubricate the seat slides with multi-purpose remove as much road grime as possible. When
grease prior to installation of the seat. polishing follow the polishing instructions which come
Install all mounting bolts by hand prior to with the polish.
tightening the mounting bolts securely. NOTE: Grease, oil or tar on the paint
surface can be removed with a little kerosene
REAR SEAT CUSHION or white spirits. To prevent staining, wash
To Remove and Install and polish the affected area as soon as the
Firmly bump the lower front of the seat grease, oil or tar is removed.
cushion rearwards and up lo release the retaining clips
from the vehicle floor panel. CLEANING VINYL TRIM
With the retaining clips released, lift the To maintain the vinyl interior trim in good
front of the seat cushion and release the rear mounting condition it should be regularly vacuumed to remove
wires. loose dirt and then wiped with a dry or damp cloth.
(3) Lift the rear seat cushion out of the vehicle. If the trim is soiled or stained, the following
Installation is a reversal of the removal procedure cleaning procedure is recommended:
with attention to the following points: Using warm water, cheese cloth and a mild
Position the centre seat belts on top of the soap, thoroughly wash the affected areas.
rear seat cushion prior to installation of the cushion. Repeat the operation using damp cheese
Ensure that the clips at the forward edge of cloth only.
the seat cushion are properly engaged in the floor To complete the cleaning operation wipe the
panel. trim over with a dry piece of cheese cloth.
REAR SEAT BACKREST NOTE: If the interior trim is badly soiled or
To Remove and Install stained, wash with a reputable brand of
upholstery cleaner carefully following the
Fold the rear seat backrest forward. makers instructions.
Remove the outer seat backrest hinge bolts.
Pull each backrest towards the door and off
the centre hinge pins. CLEANING CLOTH TRIM
Remove the rear seat backrest from the Loose dirt and dust on cloth trim should be
vehicle. removed with a vacuum cleaner or a very soft brush.
Installation is a reversal of the removal procedure. Do not use a whisk brush or any other type of coarse
brush or damage to the cloth could result. If the fabric
12. VEHICLE CLEANING is soiled the following cleaning procedure is recom-
mended.
CLEANING THE EXTERIOR Sponge the fabric lightly with warm water
containing a little detergent and household ammonia.
In order to remove dirt and road grime and thus After sponging, rub the fabric lightly. If
preserve paint finish, vehicles in continuous use soiling is still apparent, repeat the sponging operation.
should be washed at least once a week. Use a clean dry cloth to soak up excess fluid.
Before washing the paintwork, it is good policy to